Suzuki RMX250S '98-'99 Service Manual PDF

SUZUKI SERVICE MANUALFOREWORD This manual contains an introductory description on the SUZUKI RMX250S and procedures for its inspection/service and overhaul of its main components, Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motoreycle and its maintenance. Use this section as well as other sections as a guide for proper inspection and service. This manual will help you know the motorcycle bet- ter so that you can assure your customers of fast and reliable service. % This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle. + Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail + This manual is written for persons who have ‘enough knowiedge, skills and tools, includ- jing special tools, for servicing SUZUKI motorcycles. if you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you. WARNING} Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger. SUZUKI MOTOR CORPORATION Motorcycle Service Department © COPYRIGHT SUZUKI MOTOR CORPORATION 1998 GROUP INDEX GENERAL INFORMATION pt PERIODIC MAINTENANCE | 2 ENGINE | 3 FUEL AND LUBRICATION sa mnicanow sree COOLING SYSTEM coouncsrsreu chassis Ez 7 ELECTRICAL SYSTEM Ea SERVICING INFORMATION Zi RMX250SX (‘99-MODEL) zaHOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. The contents are listed on the first page of each section to help you find the item and page you need. COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided Example: Font wheel ® Speedometer gearbox © Bearing (A) © Spokes @ Tre © Spacer © Bearing (.) TEM © ® Front wheel axle © ® Spoke nipples © © Brake disc botsSYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servio- ing. The meaning of each symbol is also included in the table, SYMBOL DEFINITION | SYMBOL DEFINITION Torque control required. Data beside it indicates specified torque. ‘Apply THREAD LOCK SUPER “1303. 99000-32030 Apply oll. Use transmission oil unless otherwise specified. ‘Apply THREAD LOCK SUPER “1360” 99000-32130 ‘Apply SUZUKI SUPER GREASE “ 99000-25010 ‘Apply or use brake fluid. ‘Apply SUZUKI MOLY PASTE. 99000-25140 Measure in voltage range. AGH AGH AGH ‘Apply SUZUKI SILICONE GREASE. 99000-25100 Measure in resistance range. ‘Apply SUZUKI BOND “1215” 99000-31110 Use special tool. © a = =a (12078) ‘Apply SUZUKI BOND “12078”. 99000-31140 Use engine coolant 99000-99032-10X ‘Apply THREAD LOCK SUPER "1322". 99000-32110 al ‘he ‘) << a Use fork oil '99000-99001-SS05a7 Vee eet Vale) CONTENTS WARNING/CAUTION/NOTE .. GENERAL PRECAUTIONS ... SUZUKI RMX250SW ('98-MODEL) SERIAL NUMBER LOCATION .. FUEL, OIL AND ENGINE COOLANT RECOMMENDATIONS FUEL | ENGINE OIL .. TRANSMISSION OIL .. BRAKE FLUID .. FRONT FORK OIL REAR SHOCK ABSORBER OIL ANTHFREEZE ... ENGINE COOLANT BREAK-IN PROCEDURES INFORMATION LABELS.. SPECIFICATIONS COUNTRY OR AREA ...1-1_ GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- ‘sages highlighted by these signal words, WARNING] Indicates a potential hazard that could result in death or injury. A CAUTION} Indicates a potential hazard that could result in motorcycle damage. NOTE: Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards ‘elating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN- INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice GENERAL PRECAUTIONS * Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle. * When two or more persons work together, pay attention to the safety of each other. * When it is necessary to run the engine indoors, make sure that exhaust gas is forced out- doors, * When working with toxic or flammable materials, make sure that the area you work in is well ventilated and that you follow all of the manufacturer's instructions. + Never use gasoline as a cleaning solvent. + To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system until they have cooled. * After servicing the fuel, oil, engine coolant, exhaust or brake systems, check all of the lines and fittings related to the system for leaks.GENERAL INFORMATION _ 1-2 A CAUTION * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order. Be sure to use special tools when instructed. Make sure that all parts used in reassembly are clean. Lubricate them when specified. Use the specified lubricant, bond, or sealant. When removing the battery, disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable, and cover the positive terminal with the terminal cover. * When performing service to electrical parts, disconnect the battery negative cable unless the service procedure requires the battery power. * When tightening cylinder head and crankcase bolts and nuts, tighten the larger sizes first. Always tighten the bolts and nuts from the inside working out, diagonally and to the sp. fied tightening torque. * Whenever you remove oil seals, gaskets, packing, O-rings, self-locking nuts, locking washers, cotter pins, circlips, and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces. % Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. * Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them. * After reassembling, check parts for tightness and proper operation. RRR RE » To protect the environment, do not unlawfully dispose of used motor oil, engine coolant, all other fluids, batteries, and tires. * To protect the earth's natural resources, properly dispose of used motorcycles and parts.1:3 GENERAL INFORMATION SUZUKI RMX250SW (’98-MODEL) RIGHT SIDE LEFT SIDE nce between photographs and the actual motoroyles depends on the markets, SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) @ is stamped on the steering head pipe. The engine serial number @ is stamped on the crankcase assembly. These numbers are required especially for registering the machine and ordering spare parts. = Dit FUEL, OIL AND ENGINE COOLANT RECOMMENDATIONS Be sure to use the specified fuel, oils, and engine coolant. Fuel, oil, and engine coolant specifications are listed below. FUEL Use only unleaded gasoline with a minimum grade of 95 octane (RON). ENGINE OIL B.P. RACING 2T-R, SHELL SPORTS SX, MOTUL 800 2T, CASTROL A747 or equivalent Two Cycle Rac- ing Lubricant A CAUTION | * A mixture cont too little oil will cause piston seizure. Too much oil will cause excessive carbon build-up resulting in preignition, a fouled spark plug and loss of engine power. + Make sure the fuel and engine oil mixture ratio is 32:1.GENERAL INFORMATION 1-4 TRANSMISSION OIL Use a good quality SAE 10W/40 multi-grade motor oil BRAKE FLUID Use DOT 4 brake fluid. A WARNING This motorcycle uses a glycol-based brake fluid. Do not use or mix different types of brake fluid such as silicone-based and petroleum-based fluids for refilling the system, otherwise serious damage will result to the brake system. Never use any brake fluid taken from old, used or unsealed containers. Never re-use brake fluid left over from the last servicing or which has been stored for a long period of time. FRONT FORK OIL. Use fork oil SS-05 or an equivalent fork oil REAR SHOCK ABSORBER OIL Use rear suspension oil SS-25 or an equivalent rear suspension oll ANTI-FREEZE Use antreeze whish is designed for use in aluminum radiators. Anti-freeze performs as a corrosion and rust inhibitor, a water pump lubricant, as well as an anti-reezing solution. Therefore, always use anti-freeze in the engine coolant, regardless of if the atmospheric temperature in your area does not go below the freezing point. ‘The percentage of anti-freeze in the engine coolant, should be between 50-60%. If the percent- ‘age of anti-freeze is below 50%, the engine coolant’s anti-freezing and rust ing capabili- | ties will be reduced. Always keep the anti-freeze content above 50%, even though the atmospheric temperature might not go below the freezing point. ENGINE COOLANT Mix only distilled weter with the anti-freeze, since other types of water can corrode and clog the aluminum radiator. For detailed information on the engine coolant mixture, refer to the cooling system section on page 5-2. Engine coolant quantity (total): 1170 ml (1.3 US qt/1.1 Imp at) BREAK-IN PROCEDURES During manufacturing only the best possible materials are used and all machined parts are finished to a very high standard. Itis stil necessary to allow the moving parts to “break-in” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. Refer to the following break-in throttle position recommendations, Initial 800 km: Below "/p throttle Up to 1600km: Below 3/, throttle ‘* Upon reaching an odometer reading of 1600 km, you can subject the motorcycle to full throttle operation, for short perods of time15_GENERAL INFORMATION INFORMATION LABELS THES] PRETTY OF CASTLE FD COMMENDED. Se ten DUE PROPORTION PREM i DUSSENCE CT ULC HRCOMMAEEGENERAL INFORMATION 1-6 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ns. nn 2 260mm (89.0 in) Overall width. 880 mm (34.6 in) Overall height sve 1 275mm (50.2 in) Wheelbase. 1.480 mm (68.3 in) Ground clearance. 325 mm (12.8 in) Seat height... 945 mm (37.2 in) Dry mass... 113 kg (249 Ibs) ENGINE TYP 2 sens ..Two-stroke, liquid-cooled Intake system Crankcase reed valve Number of cylinders......1 Bore 67.0 mm (2.637 in) Stroke sssosnnee 70.8 mm (2.787 in) Displacement 249 om® (15.2 cu. in) Compression ratio... 8.3: 110.3: 1 Carburetor... KEIHIN PU38, single Air cleaner... ..Polyurethane foam element Starter system 0... Primary kick Lubrication systern...... Fuel/oil premixture of 32 : 1 TRANSMISSION Cluteh Wet, multi-plate type Transmission ........5-speed constant mesh Gearshift pattern........ t-down, 4-up Primary reduction rato... 2.652 (61/23) Gear ratios, 1st (low) ..2.285 (32/14) 2d. sn 1.788 (26/15) 3rd. 1.375 (22/16) 4th 1.090 (24/22) 5th (top) ...0.863 (19/22) Final reduction ratio.....3.846 (50/13) Drive chain. RK520SMOZ9, 114 links CHASSIS Front suspension Rear suspension.. Caster... Trail Steering Angle wn ernnn Tuming radius Front brake. Rear brake Front tire size Rear tire Size... ELECTRICAL Ignition type. Ignition timing Spark plug Generator. Headlight. Tum signal light, Brake light/ailight Speedometer light... Neutral indicator light High beam indicator light True signal indicator light CAPACITIES Fuel tank including reserve. Reserve. Transmission oil Engine coolant... % These specifications are subject to change without notice. Telescopic, coil spring, oil damped, spring preload fully adjustable, compression damping force 18-way adjustable, rebound damping force 14-way adjustable Link type, gas/coil spring, oil damped, spring preload fully adjustable, compression damping force 21-way adjustable rebound damping force 26-way adjustable 28° 111 mm (4.4 in) 45° (right & left) 2.3 m (7.5 f) Disc Disc .8,00-21 51P, tube 120/90-18 65P, tube Electronic ignition (CDI) 4° B.T.D.C. at 1500 r/min NGK BP9EV Flywheel magneto 12V 6O/S5W 12V 21W 12V 21/5W 12V 1.70 12V 2W 12V 2W 12V 2W 11.51 (3.0/2.5 US/ Imp.gal) 2.5L (0.7/0.5 US/Imp.gal) 650 mi (0.7/0.6 US/Imp.qt) 1.2L (1.3/1.1 US/Imp.at)4-7_GENERAL INFORMATION COUNTRY OR AREA ‘The code on the left, stand for the country or area on the right. CODE ‘COUNTRY OR AREA E24 AustraliaPERIODIC MAINTENANC, CONTENTS — PERIODIC MAINTENANCE SCHEDULE... PERIODIC MAINTENANCE CHART... LUBRICATION POINT: MAINTENANCE AND TUNE-UP PROCEDURE .. CYLINDERHEAD, CYLINDER AND EXHAUST VALVE. ‘SPARK PLUG.. AIR CLEANER... CARBURETOR .. FUEL HOSE. CLUTCH... TRANSMISSION OIL... COOLING SYSTEM.. DRIVE CHAIN. BRAKE: TIRES AND WHEELS . STEERING . FRONT FORK. REAR SUSPENSION... EXHAUST PIPE BOLTS AND MUFFLER BOLTS. CHASSIS NUTS AND BOLTS...24 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motoroycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months, and are dependent on whichever comes fist. NOTES: ‘More frequent servicing may be performed on motorcycles that are used under severe conditions. PERIODIC MAINTENANCE CHART Interval |_km 1000 ‘5000 70000 15000 miles 600 3000 6000 9500 Item month(s) 1 5 10 15 Cylinder head, cylinder and exhaust valve c c c c ‘Spark plug c R | OR R Air cleaner element Clean every 3000 km (2000 miles). Idle speed ' ! I ! I ' Throttle cable pay I 1 1 I Fuel hose I 1 1 I Replace every four years. Ciluteh I 1 D Transmission oil RO [= R 5 Radiator hoses = H H Replace every four years. Engine coolant - Replace every two years. Drive chain TT i i Clean and lubricate every 1000 km (600 miles). Brakes H H o I Brake hoses a 1 I Replace every four years. Brake fluid 1 T I Replace every two years. Steering 1 T I i Front fork H i I i ~ Rear suspension 1 H I I | Tires and wheels 1 1 I \ Exhaust pipe belts and muffler bolts T T T [| T Chassis nuts and bolis T T T T NOTE: |= Inspect and clean, adjust, replace or lubricate as necessary. R=Replece T= Tighten C=CleanPERIODIC MAINTENANCE 2.2 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. FB ove iver snout cate pivot | | Paper “By Seve cnan and spring hook By trottie carie By erate ever holder | Gu svinaam pc | | FGA ete peal pot Sat Coston lover and dustin lever 09 pot NOTE: * Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, drt or grime. * Lubricate exposed parts which are subject to rust, with a rust preventative spray, especially whenever the motorcycle has been operated under wet or rainy conditions.2.3 PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURE This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart. CYLINDERHEAD, CYLINDER AND EXHAUST VALVE Remove carbon initially at 1000 km (600 miles, 1 month) and every 5000 km (3000 miles, 5 months) thereafter. (See p. 3-18.) SPARK PLUG Clean initially at 1000 km (600 miles, 1 month) and replace every 5000 km (3000 miles, 5 months) thereafter. ‘© Remove the spark plug. IN Dirt can damage the engine if it enters an open spark plug hole. Cover the spark plug hole whenever the spark plug is removed. CARBON DEPOSIT Check for carbon deposits on the spark plug. To remove any carbon deposits use a spark plug cleaner machine or carefully use a tool with a pointed end SPARK PLUG GAP Use a thickness gauge to measure the spark plug gap. If out of, specification, adjust the gap. Spark plug gap (Standard): 0.5-0.6 mm (0.020-0.024 in) (09900-20803: Thickness gauge ELECTRODE CONDITION Inspect the electiodes. If they are extremely worn or burnt, replace the spark plug. If any part of the spark plug is damaged, replace the spark plug, 4 HEAT RANGE Check to see the heat range of the spark plug. 05-0.6mmPERIODIC MAINTENANCE 2-4 [A CAUTION ‘An improper spark plug may have an incorrect fit or heat range for your engine. This may cause severe ‘engine damage which will not be covered under war- ranty. Use the spark plug listed below or equivalent. Standard spark plug: NGK BRSEV @ Tighten the spark plug to the specified torque. (©) Spark plug: 27 N-m (2.7 kg-m, 19.5 Ib-ft) AIR CLEANER Clean every 3000 km (2000 miles). © Remove the seat. (See p. 6-2.) © Remove the air cleaner case cover ©. © Loosen the wing nut © and remove the air cleaner element assembly. © Separate the polyurethane foam element from the frame. , l Use a non-flammable solvent @ to clean the air cleaner element © Gently squeeze the air cleaner element to remove the excess solvent. Immerse the air cleaner element in motor oil @ and squeeze out the excess oil. The air cleaner element should be wet but not dripping, NOTE: Do not twist or wring the air cleaner element because it wil fear or the individual cells of the air cleaner element will be damaged. PN Operating the engine without the air cleaner element properly in place could allow flames to spit back from the engine to the air cleaner element, or allow dirt to enter the engine. This may could result in a cause severe engine damage.25 PERIODIC MAINTENANCE A CAUTION Clean or replace the air cleaner element frequently if the motorcycle is used in dusty, wet or muddy con tions. The air cleaner element will clog under these conditions, and this may cause engine damage, poor performance, and poor fuel economy. Clean the air cleaner case and element immediately if water gets in the air cleaner box. A torn air cleaner element will allow dirt to enter the engine and can damage the engine. Carefully examine the air cleaner element for tears during cleaning. Replace it with a new one if itis torn. NOTE: When reinstalling the air cleaner element assembly and seat, be sure to do the following. ‘* Fit the projection of the frame in the holes of the air cleaner element ‘© Install the air cleaner element assembly in the air cleaner box so the triangle projection of the air cleaner element faces the triangle projaction of the box. « After reinstalling the air cleaner case cover, insert the large mesh element between the frame and air cleaner case. © Install the seat. ‘CAU Failure to position the air cleaner element properly f can allow dirt to bypass the air cleaner element. This wv will cause engine damage. Be sure to properly install |» the air cleaner element.CARBURETOR Inspect initially at 1000 km (600 miles, 1 month) and every 5000 km (3000 miles, 5 months) thereafter. ENGINE IDLE SPEED '® Connect the tachometer to the plug cord, Start the engine and use the throttle stop sorew @ to set the engine speed between 1150 and 1250 r/min. Engine idle speed: 1200 + 50 r/min 09900-26006: Tachometer NOTE: ‘Make this adjustment when the engine is hot. THROTTLE CABLE PLAY Throttle cable play @ should be 3-6 mm (0.12-0.24 in) as measured at the throttle grip when turning the throttle grip lightly. If the throttle cable play @ is incorrect, adjust it as follows. # Loosen the lock nut @ and turn the adjuster @ in or out until the specified play is obtained. «© Tighten the lock nut @ while holding the adjuster ©. Throttle cable play @: 3-6 mm (0.12-0.24 in) FUEL HOSE Inspect initially at 1000 km (600 miles, 1 month) and every 5000 km (3000 miles, 5 months) thereafter. Replace every four years. PERIODIC MAINTENANCE 2-6 Bo OY2.7_PERIODIC MAINTENANCE CLUTCH LEVER PLAY Inspect initially at 1000 km (600 miles, 1 month) and 5000 km (3000 miles) thereafter. Clutch lever play ® should be 10-15 mm (0.4-0.6 in) as mea- surement at the clutch lever end when the clutch begins to dis- ‘engage. If the clutch lever play is incorrect, adjust it as follows. Loosen the catle adjuster lock nut @ and turn the cable adjuster @ or loosen the cable adjuster lock nut ®, and turn the cable adjuster @ in or out to require the specified play. © Tighten the cable adjuster lock nut while holding the cable adjuster in positon. Clutch lever play ®): 10-15 mm (0.4-0.6 in) NOTE: The clutch cable should be lubricated with a light weight oil whenever itis adjusted. TRANSMISSION OIL Replace initially at 1000 km (600 miles, 1 month) and every 10000 km (6000 miles, 10 months) thereatter. After a long period of use, the transmission oil will deteriorate and quicken the wear of sliding and interlocking surfaces. Replace the transmission oil periodically following the procedure below. ‘© Keep the motoreycle upright, supported by a jack or wooden block. © Start the engine to warm up the oil; this will facilitate the draining of the cil. Shut off the engine. © Place the oil pan below the engine and drain the oil by removing the filer cap © and drain plug ©. POG Engine oll and exhaust pipes can be hot enough to burn you. Wait until the oil drain plug and exhaust pipes are cool enough to touch with bare hands before draining oil. © After draining the oil completely, fit the drain plug @ securely. {© Drain plug: 13 N-m (1.3 kg-m, 9.5 Ib-ft) ‘© Remove the oil level screw ©. '® Hold the motorcycle upright and add a good quality SAE 10W/40 multi-grade motor oil until the transmission oil ‘comes out from the oil level hole.PERIODIC MAINTENANCE 2-8 A CAUTION Engine damage may occur if you use oil that does not meet Suzuki's specifications. Use the oil specified in the FUEL, OIL AND ENGINE COOLANT RECOMMEN- DATION section. TRANSMISSION OIL CAPACITY Oil change: 650 mI (0.7/0.6 US/Imp pt) Overhaul: 750 mi (0.8/0.7 US/Imp pt) © Install the filer cap and oil level screw. COOLING SYSTEM Inspect every 5000 km (3000 miles, 5 months). Replace engine coolant every two years. Replace radiator hoses every four years. ENGINE COOLANT LEVEL CHECK NOTE: This motorcycle does not have an overflow tank at the end of the breather hose. Therefore, the engine coolant level may decrease while riding. Check the engine coolant level before every ride. Remove the radiator cap © and check that the engine coolant level is at the bottom of the inlet hole. If not, replenish the radiator with the specified coolant. PRUETT) Do not open the radiator cap when the engine is hot as you may be injured by escaping hot liquid or vapor ENGINE COOLANT CHANGE ‘© Remove the radiator cap @ and drain plug ®. Then drain the engine coolant. © Tighten the drain plug ©.29 PERIODIC MAINTENANCE ‘© Pour the specified engine coolant slowly up to the radiator 4G Engine coolant capaci 1170 mi (1.3/1.1 US/Imp.qt) ‘© Tighten the radiator cap securely. A WARNING} * Do not open the engine coolant reservoir cap when hot, as you may be injured by escaping hot liquid or vapor. * Engine coolant may be harmful if swallowed ot comes in contact with the skin or eyes. If engine coolant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water. if engine coolant is swallowed, induce vomiting and call a physician immediately. RADIATOR HOSES Check the following items. ‘© Engine coolant leakage. ‘© Radiator hose cracks and deterioration. I any defects are found, the radiator hoses must be replaced, DRIVE CHAIN Inspect initially at 1000 km (600 miles, 1 month) and every 5000 km (3000 miles, 5 months) thereafter. Clean and lubricate every 1000 km (600 miles). With the transmission in neutral, support the motoreycle with a jack and a wooden block and turn the rear wheel slowly by hand. Visually check the drive chain for the possible defects listed below. * Loose pins * Excessive wear % Damaged rollers@__* Improper chain adjustment * Dry orrusted links @ * Missing O-ring seals ® * Kinked or binding links If any defects are found, the drive chain must be replaced. NOTE: When replacing the drive chain, replace the drive chain and sprockets as a setCHECKING © Loosen the axle nut ©. # Tense the drive chain fully by turing both chain adjusters ®. ‘© Count out 21 pirs (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced, Service Limit Drive chain 20-pitch length 319.4 mm, (12.57 in) ADJUSTING # Place the motorcycle on its side-stand for accurate adjustment. ‘© Tum both chain adjusters © until the chain has 45-55 mm (1.8-2.2 in) of slack halfway between the engine and rear sprockets. Align both right and left adjusters to the same position against the stoppers @ on the swingarm by refer- ring to the numbers on the adjusters. @ After adjusting the drive chain, tighten the axle nut @ to the specified torque. (8) Rear axte nut: 110 N-m (11 kg-m, 80.5 Ib-ft) CLEANING AND LUBRICATING © Clean the drive chain with kerosene. If the drive chain tends to rust quickly, the intervals must be shortened. (A GAUTION] Do not use trichloroethylene, gasoline or any similar solvent. These fluids have too great a dissolving power for this chain and they can damage the “O- ring” seals. Use only kerosene to clean the drive chain, PERIODIC MAINTENANCE 2-10 45—55 mm211_ PERIODIC MAINTENANCE «© Alter cleaning and drying the chain, oil it with a heavyweight motor oil A CAUTION % Some drive chain lubricants contain solvents and additives which could damage the “O-ring” seals in the drive chain. Use SUZUKI chain lube or an equivalent that is specifically intended for use with “O- ring” chains. * The standard drive chain is a RK520SMOZ9. SUZUKI recommends to use this standard drive chain as a replacement. Avoid using a joint clip type chain. BRAKES (BRAKE) Inspect initially at 1000 km (600 miles, 1 month) and every 5000 km (3000 miles, 5 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect initially at 1000 km (600 miles, 1 month) and every 5000 km (3000 miles, 5 months) thereafter. Replace hose every four years. Replace fluid every | wo youre, | BRAKE FLUID LEVEL © Keep the motorcycle upright and place the handlebars straight © Check the brake fluid level by observing the lower limit line cn the front anc rear brake fluid reservoir. © When the brake fluid level is below the lower limit ine, : replenish with brake fluid that meets the following specification. B specification and classification: DOTS yy e WARNING a * The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix differ- ke ent types of fluid such as silicone-based or petroleum-based fluids. Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for along period. * Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. | Check the brake hoses and hose joints for cracks | and leakage betore rang, |PERIODIC MAINTENANCE _ 2-12 BRAKE PADS, ‘The extent of brake pad wear can be checked by observing the grooved limit line on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. (See pp.6- 38 and 6-46.) A CAUTION Replace the brake pads as a set, otherwise braking performance will be adversely affected. BRAKE LEVER PLAY ‘* Loosen the lockrut ® ‘© Adjust the brake lever play by tuming the brake lever adjuster @ until the brake lever play @) is 0.1 -0.3 mm (0.004-0.01 in) at the front of the brake lever. Brake lever play @: 0.10.3 mm (0.004-0.01 in) BRAKE PEDAL HEIGHT © Loosen the locknut @. ‘© Adjust the brake pedal height by turning the brake pedal adjusting bolt @ until the pedal is 0-10 mm (0-0.4 in) @ below the top face of the footrest. Tighten the lockrut @ securely. Brake pedal height @): 0-10 mm (0-0.4 in) BRAKE PEDAL PLAY © Loosen the locknut ©. ‘© Adjust the brake pedal play by turning the brake pedal adjusting bolt @ until the brake pedal play at the front end of the pedal is 5-15 mm (0.2-0.6 in). ‘© Check that the clearance @ is at least 0.5 mm (0.02 in). ‘ Tighten the lockrut @ securely. Brake pedal play: 5~15 mm (0.20.6 in)2413 _ PERIODIC MAINTENANCE BRAKE LIGHT SWITCH ‘Adjust the rear brake light switch so that the brake light will ‘come on just before pressure is felt when the brake pedal is depressed. AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper. The presence of air is indicated by “sponginess” of the brake lever and also by lack of braking force. Considering the danger to which such trapped air exposes the machine and rider, it is essential that, after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner: «Fill the master cylinder reservoir to the top of the inspection ‘window. Replace the reservoir cap to prevent dirt from enter- ing ‘© Attach a hose to the air bleeder valve, and insert the free end of the hose into a receptacle. ‘© Front brake: Bleed air from the brake system. ‘® Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it. Loosen the air bleeder valve by turning it a quarter of a turn 80 that the brake fluid runs into the receptacle, this will remove the tension of the brake lever causing it to touch the handlebar grip. Then, close the air bleeder valve, pump and squeeze the lever, and open the valve. Repeat this process Until the fluid flowing into the receptacle no longer contains air bubbles. NOTE: While bleeding the brake system, replenish the brake fluid in the reservoir as necessary. Make sure that there is always some fluid visible in the reservoir. ‘© Close the air biseder valve, and disconnect the hose. Fill the reservoir with brake fluid to the top of the inspection window. (©) Air bleeder vaive: 8 N-m (0.8 kg-m, 6.0 Ib-ft) [A CAUTION Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials, etc.PERIODIC MAINTENANCE 2-14 '® Rear brake: The only difference between bleeding the front and rear brakes ‘s that the rear master cylinder is actuated by a pedal TIRES AND WHEELS Inspect initially at 1000 km (600 miles, 1 month) and every 5000 km (3000 miles, 5 months) thereat TIRE TREAD CONDITION Operating the motorcycle with excessively wom tires will decrease riding stab ity and consequently invite a dangerous situ- ation. Itis highly recommended to replace a tire when the remaining depth ofthe tire tread reaches the following specification. (GB 09900-20805: Tire depth gauge Tire tread depth limit: FRONT 4.0 mm (0.16 in) REAR 4.0 mm (0.16 in) TIRE PRESSURE It the tire pressure is too high or too low, steering will be adversely affected and tire wear will increase. Therefore, main- tain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows, COLD INFLATION “IRE PRESSURE | kPa | kgicm? | psi FRONT AND REAR 10 | 15 | 22 A CAUTION The standard tite fitted on this motorcycle is a 3.00-21 51P for the front and a 120/90-18 65P for the rear. The use of tires other than those specified may cause instability. It is highly recommended to use the specified tires.2.15 _ PERIODIC MAINTENANCE SPOKE NIPPLES Inspect prior to operating the motorcycle. Make sure that the nipples are tight. If necessary, retighten them with a spoke nipple wrench. {© spoke nipple: 2.5 N.m (0.25 kg-m, 1.8 Ib-ft) STEERING Inspect initially at 1000 km (600 miles, 1 month) and every 5000 km (3000 miles, 5 months) thereafter. The steering should be adjusted properiy for smooth turning of the handlebars ard safe operation. Overtight steering prevents smooth tuming of the handlebars and too loose steering will cause poor stabilly. Check that there is no play in the front fork. ‘Support the motorcycle so that the front wheel is off the ground. With the wheel facing straight ahead, grasp the lower fork tubes near the axle and pull forward. If play is found, readjust the steering. (See pp. 6-19 and 6-20.) FRONT FORK Inspect initially at 1000 km (600 miles, 1 month) and every 5000 km (3000 miles, 5 months) thereafter. Inspect the front fork for cil leakage, scoring or scratches on the cuter surface of the inner tubes. Replace any defective pars, if necessary. (See pp. 6-9 t0 6-15.) REAR SUSPENSION ally at 1000 km (600 miles, 1 month) and les, 5 months) thereaft. Inspect every 5000 km (3000 Inspect the rear shock absorbers for oll leakage and check that there is no play in the swingarm.PERIODIC MAINTENANCE 2-16 EXHAUST PIPE BOLTS AND MUFFLER BOLTS Tighten initially at 1000 km (600 miles, 1 month) and every 5000 km (3000 miles, 5 months) thereafter. Remove the frame cover (See p. 6-2.) ‘© Tighten the exhaust pipe mounting bolts and muffler mounting bolt2.17 _ PERIODIC MAINTENANCE CHASSIS NUTS AND BOLTS ight lly at 1000 km (600 miles, 1 month) and every 5000 km (3000 miles, 5 months) thereafter. Check that all chassis nuts and bolts are tightened to their specified torque. (See p.2-18 for the locations of the following nuts and bolts.) ITEM Nm kg-m Ibeft @ Handlebar clamp bolt 26 26 19.0 @ Handlebar holder nut 5 45 325 @ Front fork upper clamp bolt 26 26 19.0 @ Front fork lower clamp bolt 26 26 19.0 © Steering stem head nut _ 90 9.0 65.0 ‘Steering stem nut 45 45 32.5 @ Front fork cap bolt 23 23 165 @ Front fork center bolt 80 80 58.0 © Front brake master cylinder mounting boit 10 1.0 7.0 @ Rear brake master cylinder mounting bolt 40 1.0) 70 @ Brake hose union bolt (front & rear) 23 23 165 @ Brake caliper mounting bolt (front & rear) 26 26 19.0 @ Brake pad mounting pin (front & rear) 18 18 13.0 @ Brake air bleeder valve (front & rear) 8 os 60 (@ Rear brake pedal bolt 29 29 21.0 ® Brake disc bot (front & rear) 10 10 70 ® Front axle 7 65 65, 47.0 ® Front axle holder bott 18 18 13.0 @ Seat rail mounting bolt (upper) 26 26 19.0 @ Seat rail mounting bolt (lower) 23 23 165 @ Rear axle nut 140 11.0 795 @ Rear sprocket nut 28 28 20.0 @ Drive chain rciler mounting bolt a a4 295 @ Spoke nipple (front & rear) 25 0.25 18 © Swingarm pivot nut 79 79 57.0 ® Rear shock absorber mounting nut 55 a 40.0 (upper & lower) @ Cushion lever mounting nut (center) 100 10.0 725 @ Cushion lever mounting nut (front) 80 80 58.0 @ Cushion rod mounting nut 100, 10.0 72.5PERIODIC MAINTENANCE 2-18ENGINE CONTENTS = ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE ENGINE REMOVAL AND INSTALLATION . ENGINE DISASSEMBLY ENGINE COMPONENTS INSPECTION AND SERVICE... BEARINGS OIL SEALS CYLINDER HEAD CYLINDER 315 B15 3-16 3-18 3-18 PISTON 3-19 CLUTCH 3-21 GEARSHIFT FORK.. 3-22 CONROD CRANK | ENGINE REASSEMBLY .. CRANKSHAFT .. TRANSMISSION AND GEAR SHIFT FORK CRANKCASE GENERATOR ROTOR. GEARSHIFT SHAFT KICK STARTER 3-32 CLUTCH .. 3-34 PISTON, CYLINDER, CYLINDER HEAD AND EXHAUST VALVE... 3-36 3-23 3-23 3-24 3-24 3-25 3-28 3-30341_ ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the page listed in each section for removal and reinstallation instructions. ENGINE LEFT SIDE PARTS REMOVAL | INSTALLATION Engine sprocket 33 36 Magneto rotor 312 3:29 Stator coil 313 3:29 Carburetor 44 46 Engine sprocket cover 33 35 ENGINE RIGHT SIDE PARTS: REMOVAL | INSTALLATION Water pump 589 50 Primary driven gear ant 331 Clutch cover 39 3:35 Clutch pressure, drive and driven plates 39 3:35 Clutch sleeve hub 39 3:35 Starter idle gear ant 3:24 Exhaust valve gevernor 3-10 3:33 Gearshift shaft att 331 Gearshift cam drven gear 312 3:30 Kick crank a4 35 Kick starter 341 3:32 ENGINE CENTER PARTS REMOVAL | INSTALLATION Exhaust pipe a4 35 Cylinder head 37 3-40 Cylinder and exhaust valve 37 3-38, 39 ‘Thermostat 56 | 57 Piston 38 | 3-38 Radiators 54 55ENGINE EO ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the folowing steps. Reinstall the engine by revers- ing the removal procedure. © Drain the transmission oil. (See p. 2-7.) Remove the fuel tank. (See p. 4-2.) Remove the radiators. (See pp. 5-4 and 5-5.) Remove the carouretor. (See p. 4-4.) Disconnect the neutral switch lead wire ©. © Remove the clamps and disconnect the CDI unit couplers ®. © Remove the spark plug. (See p. 2-3.) © Disconnect the breather hose (engine side) ©.3:3 ENGINE ‘© Remove the exhaust pipe ©. Remove the engine sprocket cover @ and gearshift lever ©. @ Loosen the rear axle nut and make sure the drive chain has enough slack ©. # Remove the circlip © and engine sprocket ©.ENGINE 3-4 © Remove the kick crank @ and brake pedal ©. * Disconnect the clutch cable ©. NOTE: Remove the cotter pin before removing the brake pedal ‘* Remove the engine mounting bolts and engine mounting plates. * Partially remove the pivot shaft so that the engine can be removed. [A CAUTION Do not remove the pivot shaft completely. Pull it only enough so that the engine can be removed and that the swingarm pivot holes and frame holes stay aligned. © Gradually lower the engine.35_ ENGINE ENGINE INSTALLATION Install the engine in the reverse order of engine removal. © Insert the two long bolts from the left side. Install the brackets, spacer, bolts, and nuts properly, as ‘shown in the following illustration, NOTE: The engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use. Be sure to use new nuts and tighten them to the specified torque. TEM Nm [kgm [tbe 06.0 4a 4i_| 295 06.0.0] 8 43 | 310 ® 79 79 | 570 LENGTH 0.0.0 45 mm (18 in) @© 50 mm (2.0 in) © 102 mm (4.0 in) @ 137 mm (4 in) © =ENGINE 36 © Install the engine sprocket. NOTE: Install the engine sprocket with the flat side facing away from the engine, After remounting the engine, route the wire hamess, cables, and hoses prope'ly. (See pp. 8-8 to 8-12.) Adjust the following items to specification. Engine coolant (See pp. 2-8 and 2-9.) Throttle cable play (See p. 2-6.) Engine idle speed (See p. 2-6.) Drive chain (See pp. 2-9 and 2-10.) Clutch cable play (See p. 2-7.) Brake pedal play (See p. 2-12) '* Pour 0.65 L (0.7/0.6 US/imp at) of SF or SG classified (API) engine oil, with a viscosity rating of 10W40 (SAE), into the engine after overhauling it. ‘© Start up the engine and allow it run for several minutes at idle speed and then stop the engine. Wait a few minutes and then check that the oil level. (See p. 2-7.) Transmission oll (engine oil) change “Transmission oll (engine oil) overhaul 650 ml (0.7/0.6 USiImp at) 750 mi (0.8/0.7 US/Imp gt)3-7_ ENGINE ENGINE DISASSEMBLY © Remove the thermostat case and cylinder head. © Remove the rignt side cylinder cover. * Disconnect the exhaust valve rod (upper side). ‘@ Remove the cylinder. ‘© Remove the center cylinder cover. ‘* Remove the exhaust valve bolt @, exhaust valve levers @, collar ©, spring @, and stopper washer ©)‘¢ Remove the exhaust valve retainer @, cap @, and return spring ©. © Pull the exhaust valve shaft @ before loosing the exhaust valve shaft stopper ©) ‘* Remove the exhaust valve arm ©. # Remove the exhaust valve stopper @, spring retainer ®, and middle spring ©. ‘¢ Remove the exhaust valve. @ Exhaust valve lower @ Exhaust valve middle @ Exhaust valve guide Remove the piston pin circlip @. ‘© Remove the piston pin @ and piston ©. NOTE: Place a clean rag over the cylinder to prevent the piston pin cir clip from dropping into the crankcase. ENGINE 383.9 ENGINE ‘¢ Remove the clutch cover. ‘ Loosen the clutch spring set botts diagonally and when they are all fully loosened, remove them. * Remove the clutch pressure plate @, clutch drive plates, and clutch driven plates. © Flatten the clutch sleeve hub washer. Hold the clutch sleeve hub using the special tool and then remove the nut and clutch sleeve hub washer. (® 09920-53740: Clutch sleeve hub holderENGINE 3-10 ‘© Remove the clutch sleeve hub @. ‘© Remove the thrust washer @ and clutch housing @, ‘® Remove the collar @ and bearing ©. ‘* Remove the exhaust valve governor ®, and bearing ®. ‘* Disconnect the exhaust valve rod (lower side) after removing the exhaust valve actuator assembly.3411_ ENGINE © Disconnect the spring from the crankcase. # Remove the kick starter drive gear ©, guide ©, and spring @ ‘© Remove the magneto rotor cover. ‘© Remove the primary drive gear using the special tools. (09930-40113: Rotor holder 09930-40131: Rotor holder attachment * Remove the gearshift shaft @ and gearshift shaft stopper ©.ENGINE 3-12 ‘© Remove the gearshift cam driven gear © and gearshift cam pawl iter ©. ‘® Remove the gearshift cam stopper assembly. ‘¢ Remove the gearshift cam driven gear pin ©. ‘® Remove the magneto rotor nut using the special tools. (09930-40113: Rotor holder (09930-40131: Rotor holder attachment ‘¢ Remove the magneto rotor using the special tools. (09930-30713: Flywheel rotor remover 09930-40113: Rotor holder 09930-40131: Rotor holder attachment343 _ ENGINE ¢ Remove the stator coil assembly. ‘© Remove the reed valve. ‘© Separate the left and right crankcases using the special tool. ] [A cauTi the crankcase separator so that the tool arms are Parallel to the crankcast Remove the right crankcase from the left. The crankshaft and transmission components must remain in the left crankcase. Hf crankcase separation is difficult, lightly tap on the reinforced areas of the crankcase with a plastic ham- me (09920-13120: Crankcase separator '* Remove the gearshift cam @, gearshift forks @, and th gearshift fork shafts @.ENGINE 3-14 © Remove the countershaft @ and driveshaft ©. ‘® Remove the crarkshaft using the special tool. 09920-13120: Crankcase separator345 _ ENGINE ENGINE COMPONENTS INSPECTION AND SERVICE BEARINGS Wash each bearing with a cleaning solvent and lubricate them with motor oil before inspection. Turn each inner ring and check to see that it tums smoothly. If it does not tum quietly and smoothly, the bearing is defective and must be replaced with a new one. RIGHT DRIVESHAFT BEARING AND LEFT COUNTER- ‘SHAFT BEARING ‘© Remove the right driveshaft bearing and left countershaft bearing using the special tools. 09923-73210: Bearing remover (09930-30102: Sliding shaft A CAUTION) The removed bearings should be replaced with new ones. ¢ Install the new right driveshaft bearing and left countershaft bearing using the special tool (B® 09922-55131: Bearing installer LEFT DRIVESHAFT BEARING AND RIGHT COUNTER- SHAFT BEARING ‘* Remove the left driveshaft bearing and right countershaft bearing using the special tools (CB 09923-74510: Bearing remover (09930-30120: Sliding shaft LA CAUTION | ‘The removed bearing should be replaced with a new one. * Install the new left driveshaft bearing and right countershatft bearing using the special tool (09913-75810: Bearing removerENGINE 3-46 CRANKSHAFT BEARINGS ‘¢ Remove the crankshaft bearings using the special tools. S) 09923-74510: Bearing remover 1g should be replaced with a new © Install the new crankshaft bearings using the special tool. S) 09913-85210: Bearing installer OIL SEALS Damage to an cil seal lip may result in leakage of the air/fuel mixture or transmission oil. Inspect all of the oil seals and if any are damaged, replace them with a new one. Install the oil seals into the crankcase as shown, ‘A CAUTION The removed oil seal should be replaced with a new one. * Apply SUZUKI SUPER GREASE “A" to the oil seal lips. @H99000-25010: SUZUKI SUPER GREASE “A”3417_ ENGINE DRIVESHAFT OIL SEAL ‘¢ Remove the driveshaft oil seal from the left crankcase using the special tool B® 09913-50121: A CAUTION The removed oil seal should be replaced with a new one. seal remover When installing the driveshaft oil seal into the left crankcase, insert it slowly with the special tool. 09913-84510: Oil seal installer CRANKSHAFT OIL SEALS ‘¢ Remove the crankshaft ol seals from the left and right crankcase, using the special tool. 3) 09913-50121: Oil seal remover [A CAUTION The removed oil seals should be replaced on ith new ‘¢ When installing the crankshaft oil seal into the left and right crankeases, insert it slowly with the special tools. (GB 09913-80112: Oil seal installer (left side) (09913-70122: Oil seal installer (right side)ENGINE 3418 CYLINDER HEAD Remove carbon from the combustion chamber and clean the cylinder head. CYLINDER HEAD DISTORTION Check the gasket surface of the cylinder head for distortion, Use a straightedge and thickness gauge. Take clearance readings at several places. If any clearance reading exceeds the service limit, replace the cylinder head, (09900-20803: Thickness gauge Service Limit Cylinder head distortion: 0.05 mm (0.002 in) CYLINDER Remove carbon from the exhaust port and the upper part of the cylinder. Do not damage the surface of the cylinder wall CYLINDER BORE Measure the cylinder bore with the cylinder gauge at 20 mm (0.8 in) from the top of the cylinder. (3) 09900-20508: Cylinder gauge set Standard Cylinder bore: 67.000-67.015 mm (2.6377-2.6384 in) CYLINDER BLOCK DISTORTION Check the gasket surface of the cylinder for distortion. Use a straightedge and thickness gauge. Take clearance readings at several places. If any clearance reading exceed the service limit, replace the cylinder. ® 09900-20803: Thickness gauge Service Limit Cylinder distortion: 0.05 mm (0.002 in)3.19 _ ENGINE PISTON PISTON DIAMETER Measure the piston diameter with the micrometer at 24 mm (0.94 in) from the skirt end If the piston diameter is less than the service limit, replace the piston. (B® 09900-20203: Micrometer (50-75 mm) Service Limit Piston diameter: 68.880 mm (2.7118 in) CARBON REMOVAL Remove the carbon from the crown of the piston and piston ring grooves. After cleaning the piston ring grooves, install the pis ton rings and rota‘e them in their respective grooves to be sure that they move smoothly Carbon in a piston ring groove can cause the piston ring to get stuck, reducing engine power output. Also, replace the piston if itis scuffed. PISTON-TO-CYLINDER CLEARANCE Subtract the piston diameter from the cylinder bore. If the pis ton-to-cylinder clearance exceeds the service limit, rebore the cylinder and use an oversized piston, or replace both the cylinder and the piston. Service Limit Piston-to-cylinder clearance: 0.12 mm (0.0047 in) PISTON PIN AND PISTON PIN BORE Measure the piston pin bore inside diameter and use a micrometer to measure the piston pin outside diameter. If either is out of specification or the difference between these two measurements is more than the limits, replace both the piston and piston pin, 09900-20605: Dial calipers Service Limit Piston pin bore: 18.030 mm (0.7098 in)ENGINE 3-20 PISTON PIN O.D. Measure the piston pin outside diameter at three positions using the micrometer. If any of the measurements are out of specification, replace the piston and piston pin (09900-20205: Micrometer (0-25 mm) Service Limit Piston pin O.D.: 17.980 mm (0.7079 in) PISTON RING-TO-GROOVE CLEARANCE Install the piston rings into the piston ring grooves. Insert the thickness gauge under each piston ring and measure the piston ring side clearance. If any of the measurements exceed the service limit, replace both the piston and piston rings. SJ 09900-20803: Thickness gauge Standard Piston ring-to-groove clearance: 0.020-0.060 mm (0.0008-0.0024 in) PISTON RING FREE END GAP AND PISTON RING END GAP Measure the piston ring free end gap using vernier calipers. Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap with the thickness gauge. If any of the measurements exceed the service limit, replace the piston ring with a new one. (09900-20101: Vernier calipers (09900-20803: Thickness gauge Service Limit: Piston ring free end gap: 5.1 mm (0.20 in) Service Limi Piston ring end gap: 0.85 mm (0.033 in)321_ ENGINE CLUTCH DRIVE AND DRIVEN PLATES Measure the drive plate thickness and claw width with the ver- rier calipers. Also, measure the driven plate distortion with the thickness gauge as shown, (GB 09900-20102: Vernier calipers (09900-20803: Thickness gauge Service limi Drive plate thickness: 2.4 mm (0.094 in) Drive plate claw width: 15.3 mm (0.60 in) Driven plate distortion: 0.10 mm (0.004 in) CLUTCH SPRING FREE LENGTH Measure the free length of each clutch spring using vernier calipers. If any spring is not within the service limit, replace all of the springs. Service Limit Clutch spring free length: 45.5 mm (1.79 in) CLUTCH RELEASE BEARING Inspect the clutch release bearing for any abnormality, especially cracks. When removing the bearing from the clutch, decide whether it can be reused or if it should be replaced. Smooth engagement and disengagement of the clutch depends on the condition of this bearingENGINE 3.22 GEARSHIFT FORK GEARSHIFT FORK-TO GEARSHIFT-FORK-GROOVE CLEARANCE Measure the gearshift fork clearance in the groove of its respective gear using the thickness gauge. If the clearance exceeds the specification, replace the fork, its respective gear or both. The clearance for each of the three gearshift forks plays an important role in the smoothness and positiveness of the shitt- ing action. 09900-20803 ness gauge (09900-20102: Vernier calipers Standard Gearshift fork-to-gearshift-fork-groove clearance: 0.10-0.30 mm (0.004-0.01 Service Limit: 0.5 mm (0.02 in) in) (Clearance check Standard Gearshift fork groove =4.9 mm (0.189-0.193 in) (Groove width check Standard Gearshift fork thickness: 4.6-4.7 mm (0.181-0.185 in) Thickness check3.23 ENGINE CONROD CONROD SMALL END 1.D. Measure the contod small end inside diameter using the dial calipers. 09900-20605: calipers Service limit Conrod small end I.D.: 23.040 mm (0.9071 in) If the conrod small end inside diameter exceeds the service limit, replace the conrod, CONROD NEEDLE BEARING Inspect the needle bearing for wear or damage. If any wear or ‘damage is found, replace the needle bearing with a new one. CRANKSHAFT (CRANKSHAFT-WEB-TO-CRANKSHAFT-WEB WIDTH Measure the orankshaft-web-to-crankshaft-web width. Adjust or replace the part(s) that is out of specification. (GB 09900-20102: Vernier calipers Standard Crankshaft-web-to-crankshatt-web width: 57.0-59.0 mm (2.279-2.287 in) CRANKSHAFT RUNOUT ‘Support the crankshaft with “V" blocks. Measure the runout with a dial gauge. Excessive crankshaft runout is often responsible for abnormal engine vibration which will shorten the life of the engine, Adjust or replace the part(s) that is out of specification. (09900-20606: Dial gauge (1/100 mm, 10 mm) (09900-20701: Magnetic stand (09910-21304: V-block (100 mm) Service limit Crankshaft runout: 0.05 mm (0.002 in)ENGINE 3.24 ENGINE REASSEMBLY Reassemble the ergine in the reverse order of disassembly. The following steps require special attention or precautionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reassembling. © Install the countershatt bearing retainer. NOTE: Apply a small quantity of THREAD LOCK SUPER "1322" to the bearing retainer sorews © (©) Bearing retainer screws: 8 N-m (0.8 kg-m, 6 Ib-ft) 5 99000-32110: THREAD LOCK SUPER “1322” CRANKSHAFT ® Conrad © Crankshaft () © Crank pin © Crankshat ) © Primary dive gear © Cotter kgm | Ibett 90 | 6503.25 _ ENGINE « Install the crankshaft @ into the left crankcase using the spe- ial tools. () 09910-32812: Crankshaft installer 09911-11310: Attachment (08910-20116: Conrod holder TRANSMISSION AND GEARSHIFT FORKS @ Kick starter gear ® Low drven goat @ Top diver gear @ sré ven gear © stn devon gear © Drve shat © 2nd even goar © Engine sproket © Courershatviow deve gear © Top nve gear © 31d ave goar atnatve gear 2nd ave gear @ Goarshit shaft Gearshit lever Gearshitt cam drven gear © Gearshit sats ® Gearshit tors Gearshit cam © TEM Nm | kgm | lb ® 08 60 ® 19 19 14.0 © 8 os | 60 @ ® 2 | 23 | 165 ® 10 1.0 7.0ENGINE 3.26 Assemble the countarshaft and driveshaft in the reverse order of disassembly. Pay attention to the following points: NOTE * Before installing the gears, rotate the bearings by hand to inspect for abnormal noises and smooth rotation. Replace the bearing if there is anything unusual. * Before installing the gears, lightly coat the driveshaft and countershatt with moly paste or engine oil (engine oil. * Before installing the oil seal, apply grease to the oil seal lip. A@H99000-25140: SUZUKI MOLY PASTE A@H199000-25010: SUZUKI SUPER GREASE “A” » Never reuse acirclip. * When installing a new circlip, do not expand the end gap larger than required to slip the circlip over the shaft. * After install , make sure it is completely seated in its groove and securely fitted. NOTE: When reassembling the transmission, attention must be given to the locations ana positions of the washers and circlips. The cross-sectional view shows the correct position of the gears, washers, and circlips. (See p. 3-27.) « Fit the circlip to the side where the thrust is, as shown in the illustration. The rounded side should be against the gear surface. => Thrust Sharp edge3.27 ENGINE ms 06000 © Install the countershaft @ and driveshaft @ into the left crankcase. © Install the gearshitt forks to their respective gears,ENGINE 3.28 « Install the gearshit cam © into the crankcase. ‘© Install the gearshift fork shafts ©. CRANKCASE ‘© Clean the mating surfaces of the crankcases. © Install the dowel oins into the left crankcase. ‘© Apply engine oil to the conrod big end of the crankshaft and to the transmission gears. «Install the left crankcase bolts. Tighten the bolts a little at a time diagonally. Then, torque them to specification. (®) crankcase bolt: 11 N-m (1.1 kg-m, 8.0 Ib-ft)3:29 ENGINE MAGNETO ROTOR @ Stator coi ®Mageto rotor Nm | kgm | ib 78 78 | 565 © Install the magneto rotor. © Apply a small quantity of THREAD LOCK SUPER “1322” to the magneto retor nut ‘© Hold the magnato rotor using the special tool and tighten the magneto rotor nut to the specified torque. (09330-40113: Rotor holder 09930-40131: Rotor holder attachment +B 99000-32110: THREAD LOCK SUPER “1322” (© Magneto rotor nut: 80 N-m (8.0 kg-m, 58.0 Ib-ft)ENGINE 3.30 GEARSHIFT SHAFT © Apply THREAD LOCK SUPER “1322” to the gearshift cam driven gear pin and tighten it to the specified torque. 35GB 99000-32110: THREAD LOCK SUPER “1322” (©) Gearshift cam driven gear pin: 23 Nem (2.3 kg-m, 16.5 Ib-ft) © Tighten the gearshift cam stopper bolt to the specified torque. (©) Gearshift cam stopper bolt: 10 N-m (1.0 kg-m, 7 Ib-ft) Install each paw! into the gearshift cam driven gear. The large shoulder @) must face to the outside. Install the gearshift cam driven gear. . . Install the paw! liter ©. Apply a small quantity of THREAD LOCK SUPER “1322” to the screws and tighten them to the specified torque. x 99000-32110: THREAD LOCK SUPER “1322” (©) Paw lifter screws: 8 N-m (0.8 kg-m, 6.0 Ib-ft) ‘© Apply a small quantity of ‘THREAD LOCK SUPER “1303” to the gearshift shaft stopper and tighten it to the specified torque, ¥ 99000-32030: THREAD LOCK SUPER “1303” {© Gearshift shaft stopper: 19 N-m (1.9 kg-m, 13 Ib-ft)3.31_ ENGINE © Install the gearshift shaft return spring. © Install the gearshift shat. © Apply a small amount of SUZUKI SUPER GREASE "A" to the oil seal lip of the gearshift shaft ACAUTION SSS | Replace the gearshift shaft oil seal with a new one. NOTE: Align the center teeth ®) on the gearshift shaft with the center teeth ©) on the gearshift cam driven gear. ABH99000-25010: SUZUKI SUPER GREASE “A” ‘© Hold the magreto rotor using the special tools and tighten the primary drive gear bolt to the specified torque. (GB 09930-40113: Rotor holder (09930-40131: Rotor holder attachment {© Primary drive gear bolt: 90 N-m (9.0 kg-m, 65.0 Ib-ft) @ Install the magneto rotor cover.ENGINE 3.32 KICK STARTER wa © estow gaa ees ecae ee BE S Ne. Tew we [tem [ea ® [10 1.0 7.0 © Install the kick starter plate and stopper. © Apply a small quantity of THREAD LOCK SUPER “1322” to the bolts and tighten them to the specified torque. 4 99000-32110: THREAD LOCK SUPER “1322” ©) Kick starter stopper bolts: 10 N-m (1.0 kg-m, 7 lb-ft) ‘© When installing the kick starter drive gear onto the kick starter shaft, align the punch mark @) in the kick starter guide with the punch mark @) in the kick starter shat.3-33_ ENGINE « Install the kick starter shaft and hook the end @ of the spring onto the crankcase boss @. «Install the exhaust valve actuator assembly. A CAUTION The screws @ must be replaced with new ones. © Install the exhaust valve governor.ENGINE 3.34 CLUTCH © Clutch pressure plate © Chtch erven pate @ © Washer © Clutch sleeve nud © Clutch housing TEM Nm | kgm | ib é 65.0 ® 3 | 903.35 _ ENGINE . Install the clutch sleeve hub onto the countershatt. Hold the clutch sleeve hub using the special tool and tighten the clutch sleeve hub nut to the specified torque. Lock the nut by firmly bending the tongue of the washer. Install the clutca pressure plate. Install the sprirgs, washers, and tighten the clutch pressure plate botts diagonally, Install the clutch cover. Tighten the bolts diagonally.ENGINE 3.36 PISTON, CYLINDER, CYLINDER HEAD, AND EXHAUST VALVE ASSEMBLY oft 20.0 275 kgm 28 38 Nm ITEM3:37_ ENGINE oft 10 1.0 70ENGINE 3.38, ‘© Install each piston ring with its “R” mark facing up. ‘ Install the piston onto the connecting rod. Oil the piston pin and slide it into the piston pin hole and the connecting rod. NOTE: The arrow mark © on the piston crown must point towards the exhaust side. ‘© Cover the opening of the crankcase with a rag. Install the new piston pin circlp into the piston. Use a new gasket to prevent oil leakage. © Install the exhaust valve. [A CAUTION Install the exhaust valve with the notched side facing up. «Install the exhaust valve shaft and arm. © Apply a small quantity of THREAD LOCK SUPER “1322” to the screw © and tighten it to the specified torque, 5 99000-32110: THREAD LOCK SUPER “1322” (© Exhaust valve shaft stopper screw @: 10 Nem (1.0 kg-m, 7 Ib-ft)339 _ ENGINE ‘© Align the slot in the exhaust valve cap with the notch in the exhaust valve shaft and install the assembly. ¢ Tum the exhaust valve cap 180° and install the bolts. © Apply a small quantity of THREAD LOCK SUPER"1322" to the exhaust valve bolt. 99000-32110: THREAD LOCK SUPER “1322” © Install the center cylinder cover. NOTE: Install the gasket and the center cylinder cover bolt ®) as shown. Apply engine oil onto the piston and the inside walls of the cylinder. Install the cylinder. Install the dowel pins and cylinder head gasket. Tighten the cylinder nut to the specified torque. ©) cylinder nut: 38 N-m (3.8 kg-m, 27.5 Ib-ft) © Install the right side cylinder cover.ENGINE 3-40 «© Install the cylinder head gasket. [A CAUTION Face the projection towards the inlet. ‘© Tighten the cylinder head nut to the specified torque. () cylinder head nut: 28 N-m (2.8 kg-m, 20.0 Ib-tt)FUEL AND LUBRICATION SYSTEM CONTENTS FUEL VALVE FUEL VALVE MECHANISM .. FUEL FILTER INSPECTION AND CLEANING FUEL TANK AND OIL TANK .. REMOVAL CARBURETOR SPECIFICATIONS CARBURETOR I.D. No. .. REMOVAL ... DISASSEMBLY INSPECTION .. NEEDLE VALVE INSPECTION FLOAT HEIGHT ADJUSTMENT .. REASSEMBLY AND REMOUNTING .. 2HOa4-1_ FUEL AND LUBRICATION SYSTEM FUEL VALVE FUEL VALVE MECHANISM The fuel valve has a lever that can be set to three positions: "ON", “OFF”, and "RES" When the lever is turned to the "ON" position, the main passage is opened. When the lever is turned to the “OFF” position, both passages are closed, © Turn the fuel valve lever to the “OFF” position and discon- Rect the fuel hose from the fuel valve. © Place a clean cil pan under the fuel valve, turn the lever to the "RES" position and drain the fuel. ‘Remove the fuel valve securing screws. ‘+ Remove the fuel valve. ‘A WARNING ine is highly flammable and explosive. heat, sparks and flames away from gasoline.FUEL AND LUBRICATION SYSTEM 4-2 FUEL FILTER INSPECTION AND CLEANING ‘¢ Remove the fuelvvalve. (See p. 4-1.) If the fuel filter is dirty with sediment or rust, fuel will not flow smoothly and a loss in engine power may result. Clean the fuel filter using compressed air. Also, check the fuel filter for cracks. PRUE * Gasoline is very explosive. Extreme care must be taken. * Gaskets and O-rings must be replaced ones to prevent fuel leakage new | | FUEL TANK REMOVAL Gasoline is very explo: Extreme care must be taken. ‘¢ Remove the seat and radiator covers. (See p. 6-2.) ‘© Tum the fuel valve lever to “OFF” and disconnect the fuel hose ©, © Remove the fuel tank by removing the mounting bolts and unhook the fuel tank band.43 FUEL AND LUBRICATION SYSTEM CARBURETOR ce © Top cap © sping Thre cable holder © Jetneede @ Trottoveve ( Saran © Photascow 6 Pastel 8 Nant © Float Maint sig sone | SPECIFICATIONS mmm (in) ITEM SPECIFICATION Carburetor type. KEIHIN PJ38_ Bore size 38 1.D. No. 44E2 Idle r/min: 1150-1250 r/min Float height 16.02 1.0 (0.630.04) Main jet (MJ) #175, Main air jet (MA.J.) #200 Jet needle (J.N.) R1472L1L-2nd Cut-away_ (CA) #5 Pilot jet (Pa) #55 Bypass (BP) 0.8 (0.031) Pilot outlet (P.0.) 0.7 (0.028) Air screw (AS) 1 turn out Throttle cable play 3.0-6.0 (0.12—0.24)FUEL AND LUBRICATION SYSTEM 4-4 CARBURETOR I.D. No. REMOVAL ‘© Turn the fuel valve lever to “OFF” and disconnect the fuel hose. Remove the fuel tank. (See p. 4-2.) Loosen the carburetor clamp screws. Remove the carburetor @. Remove the top cap © along with the throttle vaive. DISASSEMBLY @ Remove the throttle cable from the slit in the throttle valve and then remove the throttle valve ©, jet needle and throttle valve spring @. ‘© Remove the throttle cable holder @ and jet needle @ from the throttle valve ©. NOTE: When removing the throttle cable holder, push and tum 90°45 FUEL AND LUBRICATION SYSTEM ‘© Remove the float chamber ©, ‘¢ Remove the main jet ring ©. © Remove the fioat © and needle valve ® by removing the float pin ©. ‘© Remove the main jet © and pilot jet ©. A CAUTION] Do not use a wire to clean the passages and use compressed Only ‘© Remove the starter valve © and pilot air screw . INSPECTION Check the following items for any damage or clogs. * Main jet * Throttle valve * Pilot jet * Float * Needle jet * Needle valve Starter valveFUEL AND LUBRICATION SYSTEM 4-6 NEEDLE VALVE INSPECTION c_ If foreign matter is caught between the valve seat and the nee- | dle vaive, the gasoline will continue flowing and overfiow. If the valve seat and needle valve are worn beyond the permissible limits, similar trouble will occur. Conversely, if the needle valve sticks, the gasoline will not flow into the float chamber. Clean the float chamber and float parts with gasoline. If the needle valve is worn, as stown in the illustration, replace it with a new oO valve seat. Clean the fuel passage of the mixing chamber with conaecr INCORRECT compressed ai. ——___________] FLOAT HEIGHT ADJUSTMENT ‘To check the float height, turn the carburetor upside down. Grad- 1 ually lower the float and observe the clearance between the float tongue and the enc of the needle valve. When the tongue just begins to contact the end of the needle valve, stop lowering the float and hold it. Then, measure the float height from the float chamber mating surface. Use vernier calipers to measure the float height. Bend the tongue as necessary to bring height @) to the proper spesification NOTE: When measuring the float height, remove the O-ring. (B 09900-20101: Vernier cali Float height @: 16.0:1.0 mm (0.63::0.04 REASSEMBLY AND REMOUNTING Reassemble and remount the carburetor in the reverse order of removal and disassembly. Pay attention to the following points: © Adjust the pilot air screw. (See p. 4-3.) © Install the throttle valve along with the top cap. Install the throttle valve with its cutaway @ facing towards the inlet side. © ‘Install the carburetor. © Align the carburetor projection @ with the slit @ in the carburetor joint. * After remounting the carburetor, the following adjustments are necessary. % Throttle cable olay... See p.2-6. » Engine idle speed. See P26,COOLING SYSTEM ——_—___—_—_—— _ CONTENTS COOLING SYSTEM . ENGINE COOLANT . RADIATOR THERMOSTA‘’ WATER PUMP .. 52 53 565-1_COOLING SYSTEM COOLING SYSTEM DESCRIPTION The engine in this motorcycle is liquid cooled with passages in the cylinder, cylinder head, and radiator to allow the engine coolant to continually circulate during operation. The cooling system consists of a light- weight-aluminum radiator, a high-capacity and centrifugal water pump. Refer to the following illustration for the cooling system routes. —t de Hoses | <5 Cooled waterCOOLING SYSTEM 5.2 ENGINE COOLANT At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection, excellent heat protection, and will protect the cooling system from freezing et temperatures above ~31°C (-24°F) If the motorcycle will be exposed to temperatures below -31°C (-24°F), the percentage of antifreeze should be increased to 55% of 60%, according to figure 2. @ The characteristics of different anti-freeze vary; therefore, read the label on the anti-freeze container carefully. ——— * Use a high-quality ethylene-glycol-based anti-freeze, mixed with distilled water. Do not mix alcohol-based anti-freezes or different brands of anti-freeze. + Do not add more than 60% or less than 50% of anti- freeze into the engine coolant. CRUZI * The engine must be cool before servicing the cooling system. * You can be injured by scalding fluid or steam if you ‘open the radiator cap when the engine is hot. Wait until the engine has cooled before removing the radiator cap. * If engine coolant contacts the skin, wash it thor- ‘oughly with water * If engine coolant gets into the eyes, flush them with water and immediately call a physician. + Ifengine coolant is swallowed, induce vomiting and call a physician immediately. * Keep engine coolant away from children. 3180 : reajuco fois 3 E also oe 2 oe eH [is 8 nan zfioo re | O02 808 Density 6) Fig. 1 Engine coolant density-boiling point curve “eA L j 2040-6080 Too Density) Fig. 2 Engine coolant density-reezing point curve at} 7053 COOLING SYSTEM RADIATOR © Raslator overtiow hose © Upper raiator hese No.1 © Upper radiator hese No2 © Radiators © Radiator inlet hose @ Raiator outlet hose © Lower radiator hese © Raciator covers RADIATOR INSPECTION Before removing the radiator and draining the engine coolant, check the following, 1. Check the cooling system for leaks with a radiator tester @. Remove the radiator cap and connect the radiator tester to the filer. Pressurize the cooling system (120 kPa (12 kg/om?, 17 psi)) and check itt holds the specified pressure for 10 seconds. It the pressure decreases, check the entire cooling system for leaks. If leak is found, replace the defective part. PROGINS * Do not remove the radiator cap when the engine is hot. * When removing the radiator cap tester, put a rag on the filler to prevent the engine coolant from spray- ing out.COOLING SYSTEM 5-4 ACAUTIO! Do not exceed the radiator cap release pressure, or the radiator cap, and subsequently the radiator, can be damaged. 2 Check the radiator cap © using a radiator tester ® Attach the radiator tester to the radiator cap as shown. Slowly apply pressure to the radiator cap; do not exceed 110 £0.15 kPa (1.120.15 kgicm?, 15.6+2.1 psi). If the radiator cap does not hold the pressure for at least 10 seconds, replace it Radiator cap release pressure: 110+ 15 kPa (1120.15 kg/em?, 15.6+2.1 psi) ‘8 Check the radiator for dirt and other foreign materials. If any are found, clean the radiator using compressed air. Also, repair any bent or dented fins using a small screwdriver. 4 Check all the water hoses for cracks, flat spots, or loose connections. Replace any damaged hoses and properly tighten any loose connections. RADIATOR REMOVAL # Remove the radiator covers. (See p. 6-2.) ¢ Remove the fuel tank. (See p. 4-2.) @ Drain the engine coolant. (See p. 2-8.) * The engine must be cool before servicing the cool- | ing system. | + You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot. Wait until the engine has cooled before removing the radiator cap. + If engine coolant contacts the skin, wash it thoroughly with water. * If engine coolant gets into the eyes, flush them with water and immediately call a physician. * If engine coolant is swallowed, induce vomiting and call a physician immediately. Keep engine coolant away from children.55 COOLING SYSTEM © Disconnect the radiator hoses. ‘© Remove the radiator covers. ‘© Remove the radiators. INSTALLATION Install the radiators in the reverse order of removal. After installing the radiators, be sure to add the specified amount of engine coolant. (See pp. 2-8 and 2-9.)COOLING SYSTEM _ 5.6 THERMOSTAT REMOVAL ‘© Remove the seat and radiator covers. (See p. 6-2.) ‘© Remove the fuel tank. (See p. 4-2.) © Drain the engine coolant. (See p. 2-8.) PRUETT ing system. * You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot. Wait until the engine has cooled before removing the radiator cap. | + If engine coolant contacts the skin, wash it thoroughly with water. + Ifengine coolant gets into the eyes, flush them with water and immediately call a physician. + Ifengine coolant is swallowed, induce vomiting and call a physician immediately. + Keep engine coolant away from children. ‘* Disconnect the radiator hose. ‘© Remove the thernostat case ©, ‘© Remove the thermostat. INSPECTION Inspect the thermostat for cracks or damage. ‘Check the thermostat as follows. © Passa string @ between the flange as shown, ‘© Immerse the thermostat in a container of water and keep the thermostat suspended as shown. Slowly heat the container (e.g., on a stove) and observe the thermometer's reading5.7_COOLING SYSTEM ‘© When the thermostat's valve begins to open, record the thermometer’s reading. Make sure the thermostat's valve begins to open at the specified temperature. ‘Thermostat valve opening temperature: 60°C (140°F) ‘© Continue heating the container until the water temperature is above 75°C (167°F). ‘¢ When the water temperature reaches 75°C (167°F), the thermostat's valve should have raised 5.5 mm (0.22 in). Thermostat valve lift: over 5.5 mm at 75°C (over 0.22 in at 167°F) © If the thermos‘at is faulty in either of these two checks, replace it. INSTALLATION ‘© The air bleeder hole @ of the thermostat must face towards the intake side. ‘© Apply SUZUKI SUPER GREASE the thermostat. A@H99000-25010: SUZUKI SUPER GREASE “A” * to the rubber seal on Tighten the thermostat case bolts to the specified torque. © Thermostat case bolt: 10 N-m (1.0 kg-m, 7.0 Ib-ft) © After installing the thermostat, be sure to add the specified amount of engine coolant. (See pp. 2-8 and 2-9.) Valve liftCOOLING SYSTEM 5-8 WATER PUMP © Water inlet conduction case | 3 | § Moot coe | © Water pump ceven gear © Ciel REMOVAL AND DISASSEMBLY © Drain the engine coolant. (See p. 2-8.) Disconnect the radiator hose. ‘¢ Remove the water pump cover ©. © Disconnect the clutch cable @. Remove the kick crank © and brake pedal ©. ‘¢ Remove the cluten cover ©).5.9 COOLING SYSTEM ‘Remove the circlip and water pump driven gear ©. © Remove the pin ® and impeller shaft ©. ‘* Remove the ol seal using the special tool. ( 09913-50121: Oil seal remover NOTE: If the oil seal shows no signs of wear or damage, there is no need to remove it ‘© Remove the circlip ®. ‘© Drive out the inner and outer water pump bearings using the special tool (® 09041-50111: Bearing remover A CAUTION] ‘The removed bearing should be replaced with a new one. NOTE: If the bearing makes no abnormal noises or shows no signs of wear or damage, there is no need to remove itCOOLING SYSTEM 5-10, INSPECTION WATER PUMP BEARING Tuim the inner race and check the bearing play. if abnormal noise occurs or if rough movement is noted, replace the bearing with a new one. OIL SEAL Inspect the oil seal for damage, especially the sealing face. Replace the oil sealif it shows any signs of damage or leakage. REASSEMBLY AND INSTALLATION Reassemble and remount the water pump in the reverse order of removal and disassembly. Pay attention to the following points: © Install the water pump bearings using the special tool (® 09943-88211: Bearing installer ‘© Apply SUZUKI SUPER GREASE "/ installation. 23] 99000-25010: SUZUKI SUPER GREASE “A” © Install the new oil seal with a suitable size socket as shown. to the oil seal lip before ‘© Install a new gasket and tighten the water pump cover, ‘© After installing the water pump, be sure to add the specified amount of engine coolant. (See pp. 2-8 and 2-9.)CHASSIS ———— CONTENTS SEAT, FRAME COVERS, HEADLIGHT COVER, AND RADIATOR COVERS .. a ‘CONSTRUCTION .. ‘ REMOVAL ‘ REMOUNTING FRONT WHEEL CONSTRUCTION : REMOVAL .. . INSPECTION AND DISASSEMBLY .. REASSEMBLY AND REMOUNTING.. FRONT FORK ‘CONSTRUCTION REMOVAL AND DISASSEMBLY. INSPECTION REASSEMBLY AND REMOUNTING SUSPENSION SETTING STEERING: ‘CONSTRUCTION .. REMOVAL AND DISASSEMBLY. INSPECTION AND DISASSEMBLY .. REASSEMBLY AND REMOUNTING REAR WHEEL ... ‘CONSTRUCT REMOVAL INSPECTION AND DISASSEMBLY .. REASSEMBLY AND REMOUNTING. REAR SUSPENSION ‘CONSTRUCTION .. REMOVAL .. INSPECTIOI REASSEMBLY .. REMOUNTING .. FINAL INSPECTION AND ADJUSTMEN} ‘SUSPENSION SETTING FRONT BRAKE .. CONSTRUCTION .. BRAKE PAD REPL, BRAKE FLUID REPLACEMENT BRAKE CALIPER REMOVAL AND DISASSEMBLY BRAKE CALIPER INSPECTION BRAKE CALIPER REASSEMBLY AND REMOUNTING .. BRAKE DISC INSPECTION MASTER CYLINDER REMOVAL AND DISASSEMBLY .... MASTER CYLINDER INSPECTION .. MASTER CYLINDER REASSEMBLY AND REMOUNTING REAR BRAKE .... . ‘CONSTRUCTION .. BRAKE PAD REPLACEMENT BRAKE FLUID REPLACEMENT BRAKE CALIPER REMOVAL AND DISASSEMBLY BRAKE CALIPER INSPECTION ... BRAKE CALIPER REASSEMBLY AND REMOUNTING MASTER CYLINDER REMOVAL AND DISASSEMBLY .. MASTER CYLINDER INSPECTION .. MASTER CYLINDER REASSEMBLY AND REMOUNTING FITARNS OOMGRGnnHan6-1_CHASSIS SEAT, FRAME COVERS, HEADLIGHT COVER, AND RADIATOR COVERS CONSTRUCTION ZS © Heactignt cover KL © Radiator cover (R) Radator, e @ Radiator cover (L) | ® ® © Frame cover (R) % © Frame cover (L)CHASSIS 6.2 REMOVAL ar SEAT ‘¢ Remove the seat ©. 1 FRAME COVERS * Remove the seat. (See p. 6-2.) # Remove the frame covers ©, HEADLIGHT COVER ‘© Remove the headlight cover ©. RADIATOR COVERS: ‘¢ Remove the radiator covers ©. REMOUNTING Remount the seat, frame covers, headlight cover, and radiator covers in the reverse order of removal.63 CHASSIS FRONT WHEEL CONSTRUCTION ic} mem | Nm | kgm | ibft @ | 8 | 65 | #70 ® | 25 | 02 | 20 | Lo» [10 | 70 © Speedometer geartox © Bearing () © Spokes, @ Tre © Spacer © Bearing (L) © Ollseal Fim © Brake aise @ Spacer © Disc cover ® Front whee! axle ® Spoke ripples © Brake disc botsCHASSIS_64 REMOVAL © Remove the disc cover ©. ‘© Disconnect the speedometer cable ©. ‘® Loosen the front axle holder bolts @ and front axle ©. ‘© Raise the front wheel off the ground using a jack or wooden block. Remove the spacer ©, speedometer gearbox ©), front axle, and front wheel. LA CAUTION Do not operate the front bral le the front wheel is ‘© Remove the brake disc. ‘¢ Remove the oil seal ©.65 CHASSIS INSPECTION AND DISASSEMBLY ‘SPEEDOMETER GEARBOX DUST SEAL Inspect the speedometer gearbox dust seal for damage. If any damage is found, replace the speedometer gearbox. WHEEL RIM Make sure the wheel rim runout does not exceed the service limit when checked as shown. ‘An excessive amount of runout is usually due to loose spokes ora bent rim. If properly tightening the spokes does not correct the runout, replace the wheel rim NOTE: Wom or loose wheel bearings must be replaced before attempting to true a wheel rim. 2.0 mm (0.08 in) ‘SPOKE NIPPLES Make sure all the nipples are tight and retighten them as neces- ‘sary using a spoke nipple wrench. (©) Spoke nipple: 2.5 N-m (0.25 kg-m, 2.0 Ib-ft)CHASSIS 6-6 WHEEL BEARINGS Play Inspect the play of the wheel bearings by hand while they are in the wheel. Rotate :he inner race by hand to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. Remove the wheel bearings as follows: © Insert the bearing remover attachment into the wheel bearing, © Insert the wedge bar from the opposite side and lock it into the slit of the bearing remover attachment. © Drive out the wheel bearing by striking the wedge bar. 3) 09941-50111: Bearing remover A CAUTION] The removed bearing must be replaced with a new one. | Play | FRONT AXLE. Using a dial gauge, measure the front axle runout. If the runout exceeds the limit, replace the front axle. Service Limit: 0.25 mm (0.010 in) REASSEMBLY AND REMOUNTING Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay attention to the following | points: WHEEL BEARINGS ‘© Apply SUZUKI SUPER GREASE installation. A@®H99000-25010: SUZUKI SUPER GREASE “A’ "to the bearings before67_CHASSIS © Install the wheel bearings using the special tool. 09924-84521: Bearing installer set [A CAUTION First, install the left wheel bearing, then install the right wheel bearing. The sealed cover on the wheel bearing must face out. BRAKE DISC ‘© Make sure the brake disc is clean and free of any grease. Apply THREAD LOCK SUPER "1360" to the disc mounting bolts and tighten them to the specified torque. #3 99000-32130: THREAD LOCK SUPER “1360” (©) Brake disc bolt: 10 N-m (1.0 kg-m, 7.0 Ib-ft) NOTE: The stamped mark @ on the brake disc must face outward,CHASSIS 68 ‘SPEEDOMETER GEARBOX © Apply SUZUKI SUPER GREASE “A’ to the teeth of the speedometer gear before installing the speedometer gearbox. © Align the drive lugs © with the recesses © on the whee! hub and then ft the speedometer gearbox onto the wheel hub, A@H99000-25010: SUZUKI SUPER GREASE “A” ‘© Align the stopper © on the speedometer gearbox with the lug @ on the front fork. FRONT AXLE ‘© Tighten the front axle © to the specified torque. (©) Front axle: 65 N-m (6.5 kg-m, 47.0 lb-ft) ‘ Tighten the front axle holder bolt @ to the specified torque. (©) Front axle holder bolt: 18 N-m (1.8 kg-m, 13.0 Ib-ft)69 CHASSIS FRONT FORK CONSTRUCTION © Outer tube (A) © Spring adjuster bot © Push ros © Fork oyiner © Needle © Return spring © Inner tube @ Inner tube sie metal © Clamp © Boot ® Front fork cap bot @ Dust seal Piston rod tocknut @ Oi seal stopper ring al 23) 165 © Front axle holder bot © Oilseal © Center bot © Oil seal retainer eloje|e|g rlelz 8/8)5 xlele 3 8/8] 8 © Outertbe side metal 7s | 18 | 180 8 otters © Outertube(t) oe ED @ Centerbot assemblyCHASSIS 6-10 REMOVAL AND DISASSEMBLY Remove the fron: wheel. (See p. 6-4.) Remove the front brake caliper (See p. 6-39.) Remove the brake hose clamp screw @ and speedometer cable guide screw ©. Loosen the boot slamp screws, Remove the front fork after loosening the front fork upper and lower clamp bolts. NOTE Slightly loosen the iront fork cap bolt ® to facilitate later disassembly. ‘© Remove the boot. Remove the cap bolt out of the inner tube and slowly pull down the inner tube. Hold the piston rod focknut with a 17-mm wrench, Remove the cap bolt, washer, and spring, Invert the fork and stroke it several times to drain out the fork oil. NOTE: - Hold the fork inverted for a few minutes to drain the oil. ¢ Remove the push rod ®, needle ©, and return spring ®, =6-11_CHASSIS © Remove the locknut @. © Place the front fork in a vise with soft jaws. Clamp the right front fork’s axle holder and the left front fork's brake caliper bracket. [A CAUTION Do not over tighten the vise or the outer tube will be damaged. ‘© Remove the dust seal ® and stopper ring @. © Slowly pull out the inner tube. NOTE: Be careful not to damage the inside of the inner tube. ‘© Remove the center bolt @ using the special tool. (09940-52890: Front fork inner rod holder. ACAUTION, Do not use an impact wrench to remove the center bolt. © Remove the fork cylinder ©.CHASSIS 6-12 # Remove the following parts. ® Oilseal @ Inner tube slide metal ® Oilseal retainer © Cil lock piece © Outer tube slide metal [A CAUTION The outer and inner tube’s slide metals must be replaced along with the oil seal and dust seal when assembling the front fork. INSPECTION FORK SPRING Measure the fork spring free length. If itis shorter than the service limit, replace it with a new one. Service limit Front fork spring free length: 525.5 mm (20.7 in) INNER AND OUTER TUBES Inspect the inner tube sliding surface and outer tube sliding surface for any scuffing REASSEMBLY AND REMOUNTING Reassemble and remount the front fork in the reverse order of removal and disassembly. Pay attention to the following points: SLIDE METALS AND OIL AND DUST SEALS ‘© Hold the inner tube vertically, clean the metal groove, and install the inner tube slide metal by hand. A CAUTION lon coated surface of the inner ® ial613 _ CHASSIS © Install the oil lock piece ©, outer tube slide metal ® oll seal retainer @, and oil seal @ onto the inner tube. © Insert the inner tube into the outer tube and install the oil seal © using the special tool. (09940-52861: Front fork oil seal installer CENTER BOLT @ Apply THREAD LOCK SUPER “1322" to the center bolt and tighten it to the specified torque using the special tool SUPER, vB 99000-32050: THREAD LOCK SUPER “1322” (09940-52890: Front fork inner rod holder (©) Center bolt: 80 N-m (8.0 kg-m, 58.0 Ib-ft) LOCKNUT © Install the locktut to the specified position @) on the piston rod as shown. Locknut position (from the top of the inner rod to the top of, ie the locknut): 14 mm (0.55 in) —————eein_r} * Install the retumn spring ©, needle @, and push rod © into the piston rod ®.CHASSIS 6-14 FORK OIL, © Pour the specified fork cil into the inner tube. Fork oil type: Fork oll SSO5 99000-99001-SS05: SUZUKI FORK OIL SS05 Capacity (each leg): 639 mi (21.6/22.5 US/Imp 02) Hold the front fors in a vertical position and adjust the fork oil level using the special tool. 09943-74111: Fork I level: 109 mm (4.3 NOTE: Before adjusting the oil level, remove the fork spring and com- press the inner tube fully. FORK SPRING © Install the fork spring. NOTE: The end of the fork spring with the smaller inside diameter should be at the bottom of the front fork. Before installing the cap bolt turn the rebound damping force adjuster to the scttest position. Pull up the piston rod using the special tools. (02940-52841: Front fork inner rod holder 09940-94922: Front fork stopper plate ‘© Tighten the piston rod locknut to the specified torque. (®) Piston rod locknut: 23 N-m (2.3 kg-f, 16.5 Ib-ft)615 CHASSIS © When remounting the front fork, make sure the upper surface of the inner tube is above the upper surface of the handlebar holder at the specified height Inner tube position (from the upper surface of the inner tube to the upper surface of the handlebar holder): 10 mm (0.39 in) © Tighten the front fork lower clamp bolts @, front fork upper clamp bolt @, and front fork cap bolt © to the specified torque (© Front fork tower clamp bolt @): 26 N-m (2.6 kg-m, 19.0 lb-ft) Front fork upper clamp bolt @):26 N-m (2.6 kg-m, 19.0 Ib-ft) Front fork cap bolt ©: 23 N-m (2.3 kg-m, 16.5 Ib-ft) © Install the front brake caliper. (See p. 6-39.) © Install the front wheel. (See p. 6-8.) SUSTENSION SETTING ‘After installing the front fork, adjust the damping force as follows. [A CAUTION) ‘Always adjust both front forks evenly. * Fully tum the damping force adjuster clockwise until it is at its stitfest position © Count the number of clicks from the fully turned-in position, REBOUND DAMPING FORCE ADJUSTMENT © To increase the rebound damping (make the suspension stiffer), tum the adjuster @ in. The maximum setting (the suspension wil be at its stiffest) is 14 clicks in, COMPRESSION DAMPING FORCE ADJUSTMENT @ To increase the compression damping (make the suspension stitfer), tum the adjuster @ in. The maximum setting (the suspension will be at its stitfest) is 18 clicks in.CHASSIS 6-16 STEERING CONSTRUCTION @ Handlebar clamp © Handlebar holder © Steering stem upper bracket @ Bearing (upper) © Bearing ower) © Headlight cover bracket (R) © Headight cover bracket (L) © Steering stem. ® Handlebar clamp bots Stooring tom head nut Steering stem nut Front fork upper clamp bolts Handlebar holder nuts © Front fork lower clamp bol kgm | Ibett Nm 26 26 | 19.0 90 90 | 650 45 45 | 325 26 26 | 19.0 45 45 | 325 | 26 26 | 190 REMOVAL AND DISASSEMBLY ‘© Remove the front wheel. (See p. 6-4.) Remove the front fork. (See p. 6-10.) Remove the headlight cover screw (0. Disconnect the headlight coupler @ . . ‘© Remove the headlight assembly.617_ CHASSIS © Remove the lead wire cover @. © Disconnect each lead wire and coupler. # Disconnect the speedometer cable ©. © Remove the speedometer @, headlight relay @, and condenser ©. ‘© Remove the front fender. © Remove the brake hose cable guides and turn signal lights ©, and hom @. * Remove the handlebar holder nuts ©. * Remove the handlebar assembly. ‘* Remove the steering stem upper bracket ©.CHASSIS 6-18 ‘¢ Remove the steering stem nut using the special tool (09940-14911: Steering stem nut socket wrench (09940-14960: Steering stem nut socket ‘© Remove the steering stem lower bracket. NOTE: Hold the steering siem bracket to prevent it from falling. INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. %* Handlebar distortion » Race wear and brinelling % Bearing wear or damage % Abnormal bearing noise * Distortion of the steering stem Remove the steering stem lower bearing using the special tool, (09941-84510: Steering bearing remover [A CAUTION] The removed bearing and race should be replaced with a new one, © Drive out the steering stem upper and lower bearing outer races using the special tools. 09941-54911: 09941-7491 jearing outer race remover teering bearing installer REASSEMBLY AND REMOUNTING Reassemble and remount the steering stem in the reverse order of removal ard disassembly. Pay attention to the following points: OUTER RACES ‘© Press in the upper and lower outer races with the special tool. 09941-34513: Steering outer race installer 09924-84510: Steering bearing installer619_ CHASSIS BEARING © Press in the lower bearing using the special tool (® 09925-18010: Steering bearing installer '* Apply SUZUKI SUPER GREASE “A” to the upper and lower tapered roller bearings before remounting the steering stem, A@H99000-25010: SUZUKI SUPER GREASE “A” STEERING STEM NUT © Tighten the steering stem nut to the specified torque using the special tools. (09940-14911: Steering stem nut socket wrench (09940-14960: Steering stem nut socket ©) steering stem nut: 45 N-m (4.5 kg-m, 32.5 lb-ft) Turn the steering stem lower bracket about five or six times to the left and ight so the tapered roller bearings seat properly Tum back the steering stem nut 1/4~1/2 of a turn. NOTE: This adjustment will vary from motorcycle to motorcycle. @ Install the front forks temporarily. ‘® Tighten the steering stem head nut to the specified torque. ©) steering stem head nut: 90 N-m (9.0 kg-m, 65.0 Ib-ft) delatCHASSIS _ 6.20 HANDLEBAR ASSEMBLY © Apply THREAD LOCK SUPER “1322” to the handlebar holder nuts ©, then tighten them to the specified torque. 99000-32110: THREAD LOCK SUPER “1322” {®) Handlebar holder nuts: 45 N-m (4.5 kg-m, 32.5 lb-ft) © Install each cable, lead wire coupler, and brake hose. (See pp. 8-9 and 8-10.) © Install the front fork. (See p. 6-15.) © Install the front wheel. (See p. 6-8.) NOTE: Hold the front fork legs, move them back and forth and make sure that the steering is not loose.621_ CHASSIS REAR WHEEL CONSTRUCTION © Chain adjuster (A) @ Bearings () 8 Gicip @ Ollseal (L) ® Golar(L) © Rear axe © Chain adjuster (L) © B Rear ave nut Tem [Nm | kom | ib Brake disk bots ®_| 10 | 10 | 795 © Spoke rippos © Rear sprocket nuts ® 7% | 10 | 70 © | 25 | 0% | 20 © | 8 | 28 | 20CHASSIS 6.22 REMOVAL # Loosen the axle nut ©. ‘© Support the motorcycle with a jack. ‘© Remove the axle nut, washer, and chain adjuster ©. © Remove the chain case. © Remove the rear axle and disengage the drive chain from the rear sprocket. © Remove the rea’ wheel. A CAUTION Do not operate the brake pedal during or after rear wheel removal. | ‘® Remove the right and left spacers. ‘® Remove the brake disc ©. ‘© Remove the rear sprocket ®. ‘® Remove the right and lett oll seals © and circlips ©. [A CAUTION The removed oil seal must be replaced wi Lee623 CHASSIS _—|—,_MA INSPECTION AND DISASSEMBLY REAR WHEEL. WHEEL BEARING (See p. 6-6.) (Use the front wheel specifications and procedure.) REAR AXLE Using a dial gauge, measure the rear axle runout, If the runout exceeds the limit, replace the rear axle. Service Limit: 0.25 mm (0.010 in) ‘SPROCKET Inspect the sprocket teeth for wear. If they are worn, replace the sprockets and drive chain as a set. Normal wear Excessive wearCHASSIS 6.24 REASSEMBLY AND REMOUNTING Reassemble and remount the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: WHEEL BEARING * Apply SUZUKI SUPER GREASE “A” to the bearings before installing, €x199000-25010: SUZUKI SUPER GREASE “A” Install the wheel bearings using the special tool. (GB 09924-84521: Steering outer race installer NOTE: First install the right whee! bearing, then install the left whee! bearings. The sealed cover on the bearing must face out. Refer to the figure below. REAR SPROCKET @ Tighten the sprocket mounting nuts to the specified torque. (©) Rear sprocket nut: 28 N-m (2.8 kg-m, 20.0 Ib-ft) NOTE: The stamped mark@ on the sprocket must face out.6.25 CHASSIS BRAKE DISC © Make sure thet the brake disc is clean and free of any grease. Apply THREAD LOCK SUPER "1360" to the disc mounting bolts and tighten them to the specified torque. ‘S@ 99000-32130: THREAD LOCK SUPER “1360” (©) Brake disc bolt: 10 N-m (1.0 kg-m, 7.0 Ib-ft) NOTE: The stamped mark @ on the brake disc must face out. REAR AXLE © Adjust the drive chain slack after installing the rear wheel. (See p. 2-10.) © Tighten the rear axle nut @ to the specified torque. (©) Rear axle nut: 110 N-m (11.0 kg-m, 79.5 Ib-ft)CHASSIS 6.26 REAR SUSPENSION CONSTRUCTION @ Rear shock absorber assembly © Dust sea @ Washer @ Spacer © Bearing @ Cushion ros © Cushion lever @ Chain case © Disc cover ® Swingarm © Cotar @ Dust seal @ Washer @ Bearing & Chain butter @ Chain ude Toit] @ Rear shock absorber mounting nuts (upper and iower) ® Cushion rod mounting rut 5S | 55 | 40.0 | © Cushion ever mounting nut (conter) © Cushion ever mounting nut (rot) © Prot shat nt a g z 5 & 3 @)9)|O|@|6) 3627 _ CHASSIS ater ese Yee © 1)CHASSIS 6.28 REMOVAL Remove the seat and frame cover. (See p. 6-2.) ‘¢ Remove the rear wheel. (See p. 6-22.) ‘¢ Remove the rear brake caliper. (See p. 6-39.) Remove the chain guide ©). Remove the clamps and disconnect the rear brake light coupler ® and rear turn signal light couplers ©. © Remove the clamp and disconnect the side-stand switch coupler @. ‘* Loosen the carburetor clamps on the ai cleaner side. ‘¢ Remove the muffier mounting bolts.6-29 CHASSIS * Remove the seat rail mounting bolts. ‘¢ Remove the rear shock absorber ©. @ Remove the brake hose @). © Remove the cushion rod @. # Remove the swingarm pivot nut @ ‘© Remove the cushion lever ©. INSPECTION AND DISASSEMBLY REAR SHOCK ABSORBER Inspect the rear shock absorber for damage and oil leakage, and also check its bearing for excessive play.CHASSIS 630 © Loosen the locknut and spring adjuster using the special tool (09910-60611: Universal clamp wrench « Lift the spring retainer @ off of the spring and then remove it along with the C-ring ®. © Install the spring. NOTE: The end of the spring with the smaller inside diameter must be at the bottom of the rear shock absorber. REAR SHOCK ABSORBER OIL REPLACEMENT Tools and Equipment # The following tocls and equipment are required when changing the rear shock absorber oil © Screwdiver or small punch © Rags @ Vise © Nitrogen gas tank © Drain pan © Filler Hose and nozzle ® Olean @ Rguiator assembly © Beaker © Owners service manual © SUZUKI rear suspenson oll (SS-25) ‘* Remove the gas valve cap. Push the gas valve core with a screwdriver and bleed the nitrogen gas.631_ CHASSIS POCO) * Releasing high-pressure gas from the rear shock absorber is dangerous. * Do not service the rear cushion unit until the nitrogen gas pressure has been released. When releasing the gas pressure, make sure the valve is always pointed away from your face and body. To release the gas pressure, use a thin, pointed tool (e.g., screwdriver, punch) with a rag ‘over its end and press down on the gas valve core. Do not use your finger to press the core. ‘¢ Remove the compression adjuster assembly. Place a drain pan under the rear shock absorber and drain the oil. While craining the oil, slowly pump the rod, Push the gas valve core again to allow the reservoir bladder to retum to its normal condition. Pump the rod again and drain the remaining oil. Tilt the rear shock absorber as shown and add new rear suspension oil into the reservoir. il type: SUZUKI REAR SUSPENSION OIL SS-25 or equivalent. Oil capacity: 345 ml (11.7/12.1 US/Imp oz) NOTE: Be sure to fully extend the rod after adding the rear suspension oil ¢ Reassemble the compression adjuster assembly. '* Clamp the rear shock absorber in a vise with soft jaws and loosen the bleed bolt. © Inflate the reservoir bladder by slowly pressurizing the reservoir with 50 kPa (0.5 kg/cm?, 7 psi) of air. © Bleed the resevvoir of any air. ©) Air bleed bolt: 8 N-m (0.8 kg-m, 6.0 Ib-ft) ‘© Pressurize the rear cushion unit with 1000 kPa (10 kg/om?, 142 psi) of nitrogen gas. FROGONS * Using flammable gas (e.g., oxygen used for weld- 19) to pressurize the rear cushion unit is extremely hazardous and can cause a fire. * Only use nitrogen gas when refilling the rear cushion unit. However, if nitrogen gas is not available, Use compressed air which does not contain water.CHASSIS 632 WARNING} lNecYoverarsseureinaline ren TanenienlGnniimenTraoeall * Over-pressurizing the rear cushion unit may rup- ture it. * Be sure to pressurize the rear cushion unit specifi- ion. | A CAUTION The rear cushion unit's gas pressure must be set to the proper specification or the following will result: * The unit will be damaged when the motorcycle is ridden. + The unit will not operate properly. + The unit may leak oil if the gas pressure is too low. © Install the gas valve cap. DUST SEALS AND SPACERS ‘® Remove the dust seals, washers, and spacers from the swingarm, and cushion lever, and cushion rod. ‘© Inspect the spacers for any flaws or other damages. If any defects are found, replace the spacers with new ones. - ee = SWINGARM BEARINGS Insert the spacers into the bearings, move the spacer up and down and check for any play. If there is excessive play, replace the bearing(-s) with a new one. Remove the bearings and spacer using the special tools, ‘A CAUTION] The removed bearings must be replaced with new ones. SWINGARM Inspect the swingarm for damages.6.33_ CHASSIS CUSHION LEVER BEARINGS Insert the spacers into the bearings, move the spacer up and down, and check for any play. If there is excessive play, replace the bearing(-s) with a new one, ‘® Remove the cushion lever needle bearings using the special tools. (® 09923.74510: Bearing remover 09930-30102: Sliding shaft CUSHION LEVER AND CUSHION RODS Inspect the cushion lever and cushion rods for damage. PIVOT SHAFT Measure the pivot shaft runout using the dial gauge. If the runout ‘exceeds the service limit, replace the pivot shatt. ( 02900-20606: 09900-20701: (09900-2134 Service Limit ‘Swingarm pivot shaft runout: 0.3 mm (0.01 in) REASSEMBLY SWINGARM BEARINGS ‘® Before installing the bearings, install the spacer. ‘© Press the bearngs into the swingarm pivot using the special tool. (GB) 09924-84521: Bearing installer © Apply SUZUKI SUPER GREASE “A’ to the bearings. 7H99000-25010: SUZUKI SUPER GREASE “A”CHASSIS 634 CUSHION LEVER AND CUSHION ROD BEARINGS. ‘© Press the bearings into the cushion lever using the special tools. (09924-84510: Bearing installer (09941-34513: Steering outer race installer © Apply SUZUKI SUPER GREASE “A” to the bearings. REMOUNTING Remount the swingarm and rear shock absorber in the reverse order of removal. Pay attention to the following points: * Tighten each nuts to the specified torque (®) cushion lever front mounting nut @: 80 N-m (8.0 kg-m, 58.0 Ib-ft) Cushion lever center mounting nut @: 100 N-m (10.0 kg-m, 72.5 Ib-ft) Pivot shaft nut ©: 79 N-m (7.9 kg-m, 57.0 lb-ft) Cushion rod mounting nut @: 100 N-m (10.0 kg-m, 72.5 Ib-ft) ‘© Tighten the rear shock absorber mounting nuts © to the specified torque. {®) Rear shock absorber mounting nuts ©: 55 N-m (5.5 kg-m, 40.0 Ib-ft)635_ CHASSIS ‘© Tighten the seat rail mounting bolts to the specified torque. (© Seat rail mounting bolt (upper) D: 26 N-m (2.6 kg-m, 19.0 Ib-ft) ‘mounting bolt (lower) : 23 Nem (2.3 kg-m, 16.5 Ib-ft) Seat ri © Install the rear brake caliper. (See p. 6-47.) ‘© Install the rear wheel. (See p. 6-25.) ‘© Install the seat. (See p. 6-2.) FINAL INSPECTION AND ADJUSTMENT ‘After installing the rear suspension and wheel, the following adjustments are required before driving. * Drive chain (See p. 2-10.) SUSPENSION SETTING After installing the rear suspension, adjust the spring pre-set length as follows. ‘SPRING PRE-SET LENGTH ADJUSTMENT # Loosen the locknut © and turn the spring adjuster ® using the special tool (09910-60611: Universal clamp wrench Rear shock absorber spring pre-set length A): 263.8 mm (10.4 in) 2CHASSIS 6.36, REBOUND DAMPING FORCE ADJUSTMENT © To increase the rebound damping (make the suspension stifer), turn the adjuster @ in. The maximum setting (the suspension will be at its stiffest) is 26 clicks in. COMPRESSION DAMPING FORCE ADJUSTMENT ‘* To increase the compression damping (make the suspension stiffer), tum the adjuster @ in. The maximum setting (the suspension will be at its stifest) is 21 clicks in637 _ CHASSIS FRONT BRAKE CONSTRUCTION © Master cylinder reservoir cap © Diaphragm © Pistonlcup set © Master cylinder clamp © Master cylinder @ Brake hose © Brake caliper holder © Brake pads @ Soring @ Brake caliper © Brake pad pin G Brake pad pin plug @ Piston seal @ Dust seal © Brake caliper pistons @ Brake pad guide plate ® Master cylinder clamp bolts @ Brake hose union bats © Airbieeder valve © Brake caliper mounting bolts em [Nm rm | tbe ® 10 1.0 7.0 ® 23 23 | 165 © 8 08 | 60 © 26 26 19.0 WARNING * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based brake fluids. Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or which has been stored for long periods of time. When storing brake fluid, seal the container completely and keep it away from children. When replenishing brake fluid, take care not to get dust into the fluid. When washing brake components, use new brake fluid. Never use cleaning solvent. A contaminated brake disc or brake pad reduces braking performance. Discard contaminated pads and clean the disc with high quality brake cleaner or a neutral detergent. [A CAUTION Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber mater ote.BRAKE PAD REPLACEMENT ‘# Remove the disc cover. (See p. 6-4.) ‘¢ Remove the brake pads by removing the brake pad pin plug and brake pad pin @). A CAUTION * Do not operate the brake lever during or after brake pad removal. * Replace the brake pads as a set, otherwise braking performance will be adversely affected. Install the new brake pads. PEGI Make sure the brake pad is properly engaged with the guide plate @ as shown. © Tighten the brake pad pin @ to the specified torque. (©) Brake pad pin: 18 N-m (1.8 kg-m, 13.0 Ib-ft) NOTE: After replacing the brake pads, pump the brake lever a few times to cheok for proper brake operation and then check the brake fluid level. BRAKE FLUID REPLACEMENT '* Place the motorcycle on a level surface and keep the handlebar straight. ‘® Remove the master cylinder reservoir cap and diaphragm. ‘© Suck up the old brake fluid as much as possible, © Fill the reservoir with new brake fluid B Specification and classification: DOT 4 ‘© Connect a clear hose @ to the air bleeder valve @ and insert the other end of the hose into a receptacle. # Loosen the air breeder valve and pump the brake lever until the old brake fluid is completely out of the brake system. © Close the air bleeder valve and disconnect the clear hose. Fil the reservoir with new brake fluid to the upper end of the inspection window. [A CAUTION from the brake system. (See6.39 CHASSIS BRAKE CALIPER REMOVAL AND DISASSEMBLY Remove the disc cover. (See p. 6-4.) Disconnect the brake hose from the brake caliper by removing the brake hose union bolt @ and allow the brake fiuid to drain into a suitable receptacle. @ Remove the brake caliper by removing the brake caliper ‘mounting botts ©. Never reuse the brake fluid left over from previous 1g and which has been stored for long periods PGI Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces. Check the brake hose for cracks and oil leakage. ‘® Remove the breke pads. (See p. 6-38.) ‘© Remove the breke caliper holder @. ‘® Remove the sping . Place a rag over the brake caliper piston to prevent it from popping out and then force out the piston using compressed a. A CAUTION Do not use high pressure air to prevent brake caliper piston damage. ‘© Remove the piston seals @ and dust seals ©. Do not reuse the piston seals and dust seals to prevent fluid leakage.CHASSIS 6-40 BRAKE CALIPER INSPECTION BRAKE CALIPER Inspect each brake caliper cylinder wall for nicks, scratches, or other damage. BRAKE CALIPER PISTONS. Inspect the brake caliper pistons for any scratches or other damage. RUBBER PARTS The removed rubber parts @ should be replaced with new ones. BRAKE CALIPER REASSEMBLY AND REMOUNTING Reassemble and remount the brake caliper in the reverse order ‘of removal and disassembly. Pay attention to the following points: ‘© Wash the caliper bores and pistons with the specified brake fluid. Thoroughly wash the dust seal grooves and piston seal grooves. & Specification and classification: DOT 4 [A CAUTION} * Wash the brake caliper components with new brake fluid before reassembly. * Do not wipe the brake fluid off after washing the components. * When washing the components, use the speci brake fluid. Never use different types of fluid or cleaning solvents such as gasoline, kerosine, etc. * Replace the piston seals and dust seals with new ones. * Apply brake fluid to all of the seals, brake caliper bores, and pistons before reassembly. ae6-41_ CHASSIS BRAKE CALIPER SLIDE PIN © Apply SUZUKI SILICON GREASE to the brake caliper slide pins. AH.99000-25100: SUZUKI SILICONE GREASE Tighten the brake caliper mounting bolts @, brake pad pin @, and brake hose union bolt @ to the specified torque. (©) Brake caliper mounting bolt @: 26 Nom (2.6 kg-m, 19.0 Ib-ft) Brake pad pin @: 18 N-m (1.8 kg-m, 13.0 Ib-ft) Brake hose union bolt @: 23 N-m (2.3 kg-m, 16.5 Ib-ft) NOTE: Before remounting the brake caliper, push the brake caliper pistons all the way into the caliper. A CAUTION Bleed air from the system after reassembling the brake caliper. (See p. 2-13.) BRAKE DISC INSPECTION © Remove the front and rear wheels. (See pp. 6-4 and 6-22.) Check the brake disc for damage or cracks. Measure the thickness using the micrometer. Replace the brake disc if the thickness is less than the service limit or if damage is found. (By 09900-20205: Micrometer (0-25 mm) Service Limit Brake disc thickness (fron (rear .5 mm (0.10 in) 4.0 mm (0.16 in) Measure the runout using the dial gauge. Replace the disc if the runout exceeds the service limit. (09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand Service Limit Brake disc runout (front and rear): 0.3 mm (0.01 in)CHASSIS 6.42 MASTER CYLINDER REMOVAL AND DISAS- SEMBLY Place a rag uncereath the master cylinder's brake hose union bolt to catch any brake fluid that might spill. Remove the brake hose union bolt and disconnect the brake hose. A CAUTION Immediately wipe off any brake fluid contacting any part of the motorcycle. The brake fluid reacts chemically with paint, plastics and rubber materials, etc., and will damage them severely. © Disconnect the front brake light switch lead wires ©. ‘© Remove the right rear view mirror ©. ‘¢ Remove the master cylinder assembly clamp bolt @. © Remove the knuckle cover @, brake lever ©, and brake light switch ©. # Remove the reservoir cap © and diaphragm ©. Drain the brake fui. ‘* Pull the dust boot © out and remove the circlip ©.643 CHASSIS ‘¢ Remove the piston/secondary cup, primary cup, and spring. @ Piston/secondary cup @ Primary cup @ Spring MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or other damage. PISTON Inspect the piston surface for any scratches or other damage. RUBBER PARTS Inspect the primary cup, secondary cup, and dust seal for wear or damage, MASTER CYLINDER REASSEMBLY AND REMOUNTING 7 Reassemble and remount the master cylinder in the reverse a order of removal and disassembly. Pay attention to the follow- on ing points: f 1 "|| [A CAUTION S— facauTiony * Wash the master cylinder components with new brake fluid before reassembly. * Do not wipe the brake fluid off after washing the components. ‘+ When washing the components, use the specified brake fluid. Never use different types of fluid or cleaning solvents such as gasoline, kerosine, etc. * Apply brake fluid to the master cylinder bore and all of the master cylinder components before reassem-CHASSIS 6-44 ‘* When remounting the master cylinder onto the handlebar, align the master cylinder holder's mating surface with the punch mark on the handlebar and tighten the upper clamp bott first. @® Master cylinder © Master cylinder upper clamp bolt © Handlebar © Clearance © master cy \der clamp bolt (upper and lower): 10 N-m (1.0 kg-m, 7.0 Ib-ft) ‘© Tighten the brake hose union bolt to the specified torque. () Brake hose union bolt: 23 Nem (2.3 kg-m, 16.5 Ib-ft) A CAUTION Bleed air from the brake system after reassembling the master cylinder. (See p. 2-13.)6-45 _ CHASSIS REAR BRAKE CONSTRUCTION ® Airbieeder valve ® Brake hose union bots © Brake pad pin pag @ Daprragm © Master cyngor ct bots ® Brake pad pin © Revove 9 brake clper hestr oiodee ® Brake caliper bracket & Omg © Brake caliper cover Brake hose connector Tem | Nm] kgm ] mR © Spins © Greip = & Paton seats & Brake hose @ | 8 | 08 | 60 © Dust ovals Prstoneup sot S © Brake calpe piston © Push od ® | 3 | 2a | 165 @ Brake ade @ Dust boot © | 10 | 10} 70 © Master cinder resernir cap Master cynder cover FOGG * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based brake fluids. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or which has been stored for long periods of time. When storing brake fluid, seal the container completely and keep it away from children. When replenishing brake fluid, take care not to get dust into the fl When washing brake components, use new brake fluid. Never use cleaning solvent. A contaminated brake disc or brake pad reduces braking performance. Discard contaminated pads and clean the disc with high quality brake cleaner or a neutral detergent. eae ‘A CAUTION] Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials ete.BRAKE PAD REPLACEMENT ¢ Remove the brake pads along with the shims by removing the brake pad pin plug and brake pad pin ©. A CAUTION * Do not operate the brake pedal during or after brake pad removal. * Replace the brake pads as a set, otherwise braking performance will be adversely affected. Install the new brake pads. ‘Make sure the brake pad is properly engaged with the guide plate as shown in the photograph. NOTE: After replacing the brake pads, pump the brake pedal a few times to operate the brake correctly and then check the brake fluid level. BRAKE FLUID REPLACEMENT # Remove the master cylinder reservoir cap. Replace the brake fluid. (See p. 6-38.) B Specification and classification: DOT 4 A CAUTION Bleed air from the brake system. (See pp. 2-13 and 2- 14) BRAKE CALIPER REMOVAL AND DISAS- SEMBLY ‘© Remove the rear wheel (See p. 6-22.) ‘* Remove the brake caliper cover ©, brake hose union bolt ®, and allow the brace fiuid to drain into a suitable receptacle. ‘® Remove the brake caliper. A CAUTION Never reuse the brake fluid left over from previous servicing and which has been stored for long periods of time. POINTS Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces. Check the brake hose for cracks and cil leakage. ¢ Remove the brake pads. (See p. 6-46.) ‘Remove the disc cover @) @ Remove the brake caliper bracket @ and spring ©.6-47 _CHASSIS © Place a rag over the brake caliper piston to prevent it from Popping out and then force out the piston using compressed air. A CAUTION Do not use high pressure air to prevent brake caliper piston damage. © Remove the piston seals @ and dust seals Q. [A CAUTION Do not reuse the piston seals and dust seals to prevent fluid leakage. BRAKE CALIPER INSPECTION BRAKE CALIPER a (See p. 6-40.) BRAKE CALIPER PISTON .(See p. 6-40.) RUBBER PARTS (See p. 6-40.) BRAKE DISC. .(See p. 6-41.) Service Limit Brake disc thickness (rear): 4.0 mm (0.16 in) Brake disc runout (rear): 0.3 mm (0.01 in) BRAKE CALIPER REASSEMBLY AND REMOUNTING Reassemble and remount the brake caliper in the reverse order of removal and disassembly. Pay attention to the following points: ACAUTION * Wash the brake caliper components with new brake fluid before reassembly. * Do not wipe the brake fluid off after washing the components. * When washing the components, use the specified brake fluid, Never use different types of fluid or cleaning solvents such as gasoline, kerosine, etc. * Replace the piston seals and dust seals with new ones. * Apply brake fluid to all of the seals, brake caliper bores, and pistons before reassembly. n and classification: DOT 4CHASSIS 648, BRAKE CALIPER SLIDE PIN © Apply SUZUKI SILICON GREASE to the brake caliper slide pin. ABH99000-25100: SUZUKI SILICON GREASE Tighten the brake pad pin © and brake hose union bolt @ to the specified torque. (©) Brake pad pin ©: 18 N-m (1.8 kg-m, 13.0 Ib-ft) Brake hose union bolt @): 23 N-m (2.3 kg-m, 16.5 Ib-ft) © Install the rear wheel. (See p. 6-25.) NOTE: Before remounting the brake caliper, push the brake caliper pistons all the way into the caliper. A CAUTION Bleed air from the system after reassembling the brake caliper. (See pp. 2-13 and MASTER CYLINDER REMOVAL AND DISAS- SEMBLY ‘© Remove the master cylinder cover ©. ‘¢ Remove the reservoir mounting bolt ©. © Place a rag undereath the master cylinder’s brake hose union bolt to catch any brake fluid that might spill. Remove the brake hose union bolt @ and disconnect the brake hose. # Loosen the locknut @ ¢ Remove the mester cylinder along with the reservoir by removing the mounting bolts © and push rod. A CAUTION Immediately wipe off any brake fluid contacting any part of the motorcycle, The brake fluid reacts chemically with paint, plastics and rubber materials, etc., and will damage them severely. (|6-49_ CHASSIS ‘© Remove the brake hose connector @ by removing the circlip. ‘© Remove the O-ring @. [A CAUTION Replace the O-ring with a new one. © Pull the dust boot @ out, remove the circlip and push rod @. (09900-06108: Snap ring pliers. ‘© Remove the piston/primary cup set ©. MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or other damage. PISTON Inspect the piston surface for any scratches or other damage. RUBBER PARTS Inspect the primary/secondary cup and all of the rubber parts for damage.CHASSIS 6-50 MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble and remount the master cylinder in the reverse order of removal ard disassembly. Pay attention to the following points: AUTION * Wash the master cylinder components with new brake fluid before reassembly. * Do not wipe the brake fluid off after washing the components. ‘* When washing the components, use the specified brake fluid. Never use different types of fluid or cleaning solvents such as gasoline, kerosine, etc. * Apply brake fluid to the master cylinder bore and all of the master cylinder components before reassembly. i Specification and Classification: DOT 4 @ Tighten the brake hose union bolt to the specified torque before inserting the union bolt stopper @ of master cylinder groove @). (©) Brake hose union bolt: 23 N-m (2.3 kg-m, 16.5 Ib-ft) «© Tighten the master cylinder mounting bolt @ to the specified torque, {© Master cylinder set bolts: 10 N-m (1.0 kg-m, 7.0 Ib-ft) [A CAUTION * Bleed air from the system after reassembling the master cylinder. (See pp. 2-13 and 2-14.) * Adjust the brake pedal height. (See p. 2-12.)CONTENTS CAUTIONS IN SERVICING .. LOCATION OF ELECTRICAL COMPONENTS LIGHTING SYSTEM ... IGNITION SYSTEM SPEEDOMETER AND PILOT INDICATOR . LAMPS ... TURN SIGNAL RELAY ... SWITCHES7-1_ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR ‘© When disconnecting a connector, be sure to hold the terminals; do not pull the lead wires. © When connecting a connector, push it in so it is firmly attached, © Inspect the comector for corrosion, contamination and any breakage in the cover. COUPLER ‘© With a lock-type coupler, be sure to release the lock before disconnecting it When connecting a coupler, push it in until the lock clicks shut, ‘® When disconnecting a coupler, be sure to hold the coupler; do not pull the lead wires, Inspect each terminal on the coupler for looseness or bends. * Inspect each terminal for corrosion and contamination. CLAMP © Refer to “WIRE, CABLE AND HOSE ROUTING” (See P. 8- 7,) for proper clamping procedures. ¢ Bend the clamp properly, as shown in the illustration. ‘¢ When clamping the wire harness, do not allow it to hang down Do not use wire or any other substitute for the band-type clamp. SEMI-CONDUCTOR EQUIPPED PART @ Do not drop any part that contains a semi-conductor (e.g. CDI unit, regulator/rectitier. ‘¢ When inspecting the part, follow the inspection instructions carefully. Neglecting proper procedures may cause this part to be damaged. WIRING PROCEDURE © Properly route the wire hamess according to “WIRE, CABLE AND HOSE ROUTING". (See pp. 8-8 to 8-14.) conrect a INCORRECTUSING THE POCKET TESTER © Properly use the pocket tester (©) and (Q) probes. Improper use can cause damage to the motorcycle and tester. If the voltage and current values are not known, begin measuring in the highest range. ‘© After changing the resistance range, perform the 0 © adjustment. This should be done before measuring. ‘* When measuring the resistance, make sure that no voltage is applied. If votage is applied, the tester will be damaged. ‘© After using the tester, turn the switch to the OFF position. ELECTRICAL SYSTEM_7.27-3_ ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS a as so © lgnition switch ® Tum signal relay jequatorirectfier © cOl unit © Ignition cot © Magneto © Neutral switch @® Side-stand switchELECTRICAL SYSTEM 7-4 LIGHTING SYSTEM The lighting system for this motorcycle uses a magneto which is mounted on the flywheel. The lighting coils late mounted on the magneto stator and generate AC current as the magneto rotor tums. The AC current, which is generated in the charging coil, flows to the regulator/rectifier where it is changed to DC current. This DC current is then supplied to the headlight, taillight, and meter light. Regulator/rectifier Ignition switch Ly o-oo Magneto v Condenaer ony rend ay = Resistor | Headlight Tailight Meter light L TROUBLE SHOOTING {A light does not light or is not bright, Check any accessory which excessively wastes electric power. oo No installed ‘Check the continuity of the stator Cee Faulty stator coil or | No continuity —> « u coil, (See p. 7-5.) disconnected lead wire(-s). Continuity Installed > #Remove the accessory. Continued on the next page7-5_ELECTRICAL SYSTEM i | Inspect the regulator/tectifier. (See p.7-6,) bd . T ok Inspect the condenser. (See p. 7-6.) No good — ok pe INSPECTION STATOR COIL CONTINUITY INSPECTION ‘¢ Remove the fuel tank. (See p. 4-2.) ‘© Disconnect the stator coil lead wire coupler ©. Using a pocket tester, check the continuity between the three ‘Faulty regulator/rectifier. ‘Faulty condenser. #Short circuit of wire harness. Poor contact of couplers. Faulty headlight relay. lead wires. Ca} It there is no continuity, replace the stator coil with a new one. 0, (@)) Tester knob indication: x 1.9 rangeELECTRICAL SYSTEM 7-6 REGULATOR/RECTIFIER Check the continuity between the terminals. Refer to the following table. ¢ If the continuity is incorrect, replace the regulator/rectifer. (B® 02900-25002: Pocket tester ¢fB) Tester knob indication: x 1 kQ range Unit: ko @ Probe of tester to: B % | Ye | Ys o | Bw 3\|™% ‘30-150 | 30-150 20-100 $y, [0-150 30-150 20-100 8 | Ys |90-150| 30-150 20-100 E | 0 [20-100 | 20-100 | 20-100 | 10-60 Ofewi ie [| 6 | 6 | 210 CONDENSER Remove the headlight. (See p. 7-14.) ‘ Turn the ignition switch to the “ON” position to discharge the condenser. Using a pocket tester, check the continuity between the condenser lead wires ¢s follows. Red (© Probe) ~ Black/White (© Probe) Make sure the tester needle moves to 0 © and then gradually returns to =. Ifthe needle does not move to 0.2 or does not gradually return to «, replace the condenser with a new one. (BD 09900-25002: Pocket tester (GA) Tester knob indication: x 1 kQ range7-7_ELECTRICAL SYSTEM IGNITION SYSTEM DESCRIPTION In the capacitor discharged ignition system, the electrical energy generated by the magneto charges the capacitor. This energy is released in a single surge at the specified ignition timing point and the current flows through the primary side of the ignition coil. A high voltage current is induced in the secondary wind- ings of the ignitior coil, resulting in a strong spark between the spark plug gap. (ae ee 1 ct Regulator/rectifier Ignition Pick-up coll egulatortectiior (gion Ae o-7aR“oo wre Bw it Condenser} CD! unit lez jon y “ Spark . 7 plug Magneto x oh T engine stop ad Satoh 4 # TROUBLE SHOOTING No spark or poor spark Check the ignition system couplers for poor eae " P0°r | Looseness ——» Poor connection of the gennes lead wire. Correct a Check the continuity of the stator coll i — ity ee (See p. 7-5.) No continuity Faulty stator coil, Continuity Inspect the regulator/rectifier. (See p. 7-6.) ae ed OK [-— No good ——* Faulty regulator/rectifier. ’ Continued on the next page.ELECTRICAL SYSTEM 7-8 i ¥ Inspect the spark aug. (See p. 2-3.) ( _____] Correct es Inspect the ignitio coil Incorrect ——» eFaulty spark plug. Incorrect ——» eFaulty ignition coil. Correct ¥ Measure the resistance of the pick-up coil . | | (See p. 7-10.) Incorrect Faulty pick-up coil T Correct (Ar. orauity cr unit INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE ‘© Remove the fuel tank. (See p. 4-2.) ‘¢ Remove the spark plug cap. ‘© Connect a new spark plug to the spark plug cap and ground itto the crankcase. NOTE: Make sure that the spark plug cap and spark plug is connected properly. Measure the ignitior coil primary peak voltage in the following procedure. ® Connect the mult circuit tester with the peak voltage adaptor as follows. Ignition coil White/Biue terminal-Ground (@ Probe) (© Probe) NOTE: Do not disconnect the ignition coil primary wire. Z (09900-25008: Multi circuit tester set A CAUTION] When using the multi circuit tester and peak volt | adaptor, refer to the appropriate instruction manual. © Shift the transmission into neutral, turn the ignition switch to the “ON” position and grasp the clutch lever.7-9 ELECTRICAL SYSTEM @ Kick the kick srank and allow the engine to turn for a few seconds, and then measure the ignition coll primary peak voltage, © Repeat the atove procedure a few times and measure the highest ignition coil primary peak voltage. {G2 Tester knob indication: Voltage (===) Ignition coil primary peak voltage: More than 150 V WARNING] While testing, do not touch the tester probes and spark plugs to prevent receiving an electric shock. IGNITION COIL (check with the electro tester) ‘¢ Remove the fuel tank. (See p. 4-2.) © Remove the ignition coil NOTE: ‘Make sure that the three-needle sparking distance of the electro tester is set al 8 mm (0.3 in). With the tester, tast the ignition coil for sparking performance as follows. © Connect the elactro tester to the ignition coil as shown in the illustration. If no spark or an orange color spark occurs, the ignition coil may be defective. B® 02000-28107: ‘Spark performance: Over 8 mm (0.3 in) PROGINS Do not touch the wire shock when testing. lectro tester 9s to prevent an electricELECTRICAL SYSTEM 7-10 IGNITION COIL (check with the pocket tester) ‘A SUZUKI pocket tester or an ohm meter may be used, in stead of the electro tester. In either case, the ignition coil is to be checked for continuity in both primary and secondary wind- ings. Exact ohmic readings are not necessary, but, if the wind- ings are in good condition, their continuity should close to the specific values. 09900-25002: Pocket tester Ignition coil resistance Primary: 0-1 2 (® Terminal-© Ground) {{@) Tester knob indication: x 1 kQ range ‘Secondary: 15-18 0 (Plug cap-Ground) {G®) Tester knob indication: x 1 k2 range PICK-UP COIL PEAK VOLTAGE. © Remove the fuel tank. (See p. 4-2.) NOTE: ‘Make sure that all of the couplers are connected propery. # Disconnect the CDI unit coupler @ at the CDI unit Measure the pick-up coil peak voltage between the Brown and White lead wires on the CDI unit coupler. ‘© Connect the mult circuit tester with the peak volt adaptor as follows. White (® Probe)-Brown (© Probe) SJ 09900-25008: Multi circuit tester set A CAUTION When using the multi circuit tester and peak vol adaptor, refer to the ay Sr manual. © Shift the transmission into neutral, turn the ignition switch to the “ON” position and grasp the clutch lever. Kick the kick crank and allow the engine to turn for a few seconds, and then measure the pick-up coil peak voltage. Pick-up col coupler CDI unt coupler Peak vt Jadaptor7-11_ ELECTRICAL SYSTEM © Repeat the above procedure a few times and measure the highest signal generator peak voltage. ‘GB! Tester knob indication: Voltage ( Pick-up coil peak voltage: More than 2.0 V (White-Brown) If the peak voltage measured on the CDI unit coupler is lower than the standard value, measure the peak voltage on the pick- Up coil coupler a3 follows, ‘© Disconnect the pick-up coil coupler and connect the multi circuit tester with the peak volt adaptor. White terminal-Brown terminal (@ Prove) (Probe) ‘* Measure the pick-up coil peak voltage in the same manner as on the CDI unit coupler. ‘Gi! Tester knob indication: Voltage (===) ’ick-up coil peak voltage: More than 2.0 V (White-Brown) If the peak voltage on the pick-up coil lead wire couplers is within specification, but on the CDI unit coupler is out of specif cation, the wire harness must be replaced. If both peak volt- ages are out of specification, the pick-up coil must be replaced and re-checked. PICK-UP COIL © Remove the fuel tank and disconnect the pick-up coil coupler. ‘© Measure the resistance between the lead wires. If the resistance is not within the specified value, the pick-up coil must be replaced, Pick-up coil resistance: 81-121 (Brown—White) Pick con? Pick-up col couplerELECTRICAL SYSTEM _ 7-12 SPEEDOMETER AND PILOT INDICATOR REMOVE AND DISASSEMBLY # Remove the speedometer and pilot indicator. (See p. 6-17.) * Disassemble the speedometer and pilot indicator as follows. & 0 j & Wi i Using a pocket tester, check the continuity between lead wires in the diagram on the next page. If the continuity measured is incorrect, replace the respective parts. (Bd 09900-25002: Pocket tester {BP Tester knob indication: x 1 kA range NOTE: When making this test, itis not necessary to remove the speedometer and pilot indicator.7-13_ ELECTRICAL SYSTEM BAW : HIGH BEAM © (Gr: ILLUMINATION @ BIBI: NEUTRAL ©) Bilg : TURN @ 8: Black Probe of | © Probe of rem @' Cr Gray tester to: ster to a" ae BI - Black with Blue tracer LUM or Bw BIO Black with Orange tracer HIGHBEAM | aR Bw BIR. : Black with Red acer REDTRAS BO Bal BiLg ‘Black with Light green tracer — Eg BW : Black wih White racerELECTRICAL SYSTEM 7-14 LAMPS HEADLIGHT To test the fuel meter, perform the following tests. Headlight bulb: 12 V 60/55 W NOTE: Adjust the headlight (vertical and horizontal) after reassembling. BULB REPLACEMENT ¢ Remove the headlight cover. (See p. 6-2.) Remove the headlight ©, Disconnect the sacket ® and remove the rubber cap ©. Remove the bul @ by unlocking the bulb holder spring ©. Reassemble the bulb in the reverse order of removal. A CAUTION If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol or soapy water to Prevent premature bulb failure. eee7.15 _ ELECTRICAL SYSTEM TAIL/BRAKE LIGHT AND TURN SIGNAL LIGHT Tail/Brake light bulb: 12 V 5/21 W Turn signal light bulb: 12 V 21 W BULB REPLACEMENT ¢ Remove each ight lens. ¢ Push in on the bulb, turn it to the left, and pull it out. A CAUTION Do not overtighten the lens fitting screws. If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.ELECTRICAL SYSTEM _7-16 TURN SIGNAL RELAY The tum signal reay is located under the fuel tank. If the turn signal light does not light, inspect the bulb or repair the circuit connection. If the bulb and circuit connections are correct, the tum signal relay may be faulty, replace it with a new one. SWITCHES Measure the continuity of each switch with the pocket tester. If any abnormality is found, replace the respective switch assemblies with new ones. (6B 09900-25002: Pocket tester {) Tester knob indication: x 19 range IGNITION SWITCH HORN BUTTON Cale Cal Position a 2 Position S os OFF 7 | on a) PUSH =) DIMMER SWITCH FRONT BRAKE LIGHT SWITCH. Soi Soi Position My [Position 8 B HI OFF to on O—-—0 TURN SIGNAL SWITCH REAR BRAKE LIGHT SWITCH air Coir [Position ey LB Og [Position 2 wie U OFF Pua oN OE =5 a wine coLoR ENGINE STOP SWITCH B Black Br: Bown Cai Ss ey enw Be ekgeen OFF thy Light be te: Leh goon UN OF —9 O fonnge PB Ro oRea Yellow Ww White BY: Black wth Yellow racer NW: Black wih White vecer WB. White wih Black acer YW. : Yellow with White tracerERVICING INFORMATION — CONTENTS TROUBLESHOOTING WIRING DIAGRAM... WIRE, CABLE, AND HOSE ROUTING .. WIRE ROUTING CABLE ROUTING FUEL HOSE ROUTING COOLING SYSTEM HOSE ROUTING . FRONT BRAKE HOSE ROUTING .. REAR BRAKE HOSE ROUTING ant 812 | 8-14 8-15 SPECIAL TOOLS .. 816 TIGHTENING TORQUE ... 8-19 SERVICE DATA .. 8:20841_ SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint ‘Symptom and possible causes Engine will not start | Compression too low orishardto start. | 1. Worn cylinder. Replace. 2. Worn piston ring. Replace. 8. tif piston ring Repair or replace. 4. Gas leaks from the joint in crankcase, cylinder, or | Repair or replace. cylinder head. 5. Damaged read vaive. Replace. 6. Loose spark plug, Tighten. 7. Broken, cracked or damaged piston. Replace. 8. Worn crankshaft oil seal, Replace. ‘Spark plug not sparking 4. Damaged spark plug. Replace. 2. Damaged spark plug cap, Replace. 3, Fouled spark plug, Clean or replace. 4, Wet spark plug, Clean and dry or replace. 5. Defective CDI unit Replace. 6. Defective ignition col. Replace. 7. Detective stator coll Replace. 8. Open or short in high-tension cord Replace. 9. Defective ignition switch. Replace. No fuel reaching the carburetor 1 2, 3 Clogged fuel tank vent hose. Clogged or defective fuel valve. Defective needle valve, Clogged fuel hose. Clean or replace. Clean or replace. Replace with needle valve seat, Clean or replace. Engine stalls easily. Fouled spark plug. Defective CDI unit Defective ignition coil Clogged fuel hose. Clogged carburetor jet. Clogged exhaust pipe. Clean or replace. Replace. Replace. Clean. Clean. Clean.‘SERVICING INFORMATION 8-2 ‘Complaint ‘Symptom and possible causes Remedy Engine is noisy. Noise seems to come from the piston 1. Worn piston. 2. Worn eylinder. 3. Carbon build-up in combustion chamber. 4. Worn piston pin, bearing, or piston pin bore. 5. Worn piston ring or ring groove. Noise seems to come from the clutch 4. Worn countershaft spline. Replace. Replace, Clean. Replace. Replace. Replace countershatt, 2. Worn clutch hub spline. Replace clutch hub. 3. Worn clutch plate teeth Replace clutch plate, 4. Distorted clutch plate. Replace. Noise seems to come from the crankshaft 1. Worn or burnt crankshaft bearing, Replace. 2. Worn or burnt big-end bearing, Replace. Noise seems to come from the transmis 4. Worn or rubbing gear. Replace, 2. Worn countershatt spline. Replace countershatt 3, Worn driveshatt spline, Replace driveshaft 4, Worn driveshaft bearing, Replace. 5. Worn countershaft bearing. Replace. Clutch slips. 41. Clutch cable out of adjustment. ‘Adjust 2. Weak or broken clutch spring, Replace. 3. Worn or distorted clutch pressure plate, Replace. 4, Distorted clutch plate. Replace. Clutch drags. 1. Clutch out of adjustment, ‘Adjust. 2. Some clutch springs are weak, while others are not. | Replace. 3, Worn or distorted clutch pressure plate. Replace. 4, Distorted clutch plate. Replace, ‘Transmission will 1. Broken gearshift shaft return spring Replace, not shift. 2, Rubbing or stuck gearshift shaft. Replace. ‘Transmission will 1. Broken gearshift shaft return spring. Replace. not shift back. 2. Rubbing or stuck gearshift shatt. Repair or replace, 3. Worn or distorted gearshift fork. Replace. Transmission jumps | 1. Worn gear. Replace. out of gear. 2. Wom or distorted gearshift fork. Replace. 3. Weakened gearshift stopper spring Replace. 4. Worn gearshift pawl Replace gearshift fork.8.3 _ SERVICING INFORMATION Insufficient spark plug gap. Ignition not advanced sufficiently due to poorly working CDI unit Complaint ‘Symptom and possible causes Remedy Engine idles poorly. | 1. Worn cylinder. Replace. 2. Worn piston ring Replace. 3. Siti piston ring. Replace, 4. Gas leaks crankshaft oil seal Replace, 5. Excessive spark plug gap. Adjust or replace. 6. Defective CDI unit Replace, 7. Defective ignition coll Replace, 8. Defective stator coil Replace, 9. Incorrect float chamber fuel level Adjust float height 10. Clogged carburetor jt. Clean. 11. Damaged read vate. Replace, Engine runs poorlyin | 1. Worn cylinder. Replace, high-speed range. Worn piston ring Replace. Sif piston ring Replace. Regap or replace, Replace CDI unit. 8. Defective stator coil Replace, 7. Low float chamber fuel level Adjust float height. 8. Dirty air cleaner element, Clean or replace. 9. Clogged fuel hose, resulting in inadequate fuel supply | Clean and prime. to carburetor. 10, Clogged carburetor jet. Clean. Exhaust smoke is 1. Incorrect engine oil (in the fueVoil mixture), ‘Change. dirty or thick. 2. Incorrect fuel/oil mixture, Change. Engine lacks power. | 1. Worn cylinder. Rebore or replace. 2. Worn piston ring. Replace. 3. Gas leaks from crankshaft oll seal Replace. 4. Incorrect spark plug gap. Regap or replace, 5. Fouled spark plug Clean or replace. 6. Incorrect spark plug, Replace. 7. Clogged carburetor jet. Clean. 8 Incorrect float chamber fuel level Adjust float height. 9. Dirty air cleaner element Clean or replace. 10. Air leakage from intake pipe. Tighten or replace, Engine overheats. ‘Carbon build-up on piston crown. . Float chamber fuel level too low. Ar leakage trom intake pipe. Incorrect engine oil (in the fueVoil mixture) Incorrect spark plug. Clogged exhaust pipemutir. Defective cooling system, Clean. Adjust float height. Tighten or replace. Change. Change. Clean or replace. See radiator section,SERVICING INFORMATION 8-4 RADIATOR ‘Complaint Symptom and possible causes Remedy Engine overheats. | 1. Low engine cootant level. ‘Add engine cootant. 2, Clogged raciator core. Clean. 3. Stuck thermostat (in fully-closed position). Replace, 4, Clogged engine coolant passage Clean. 5. Airtrapped in the cooling crcut. Bleed. 6. Defective water pump. Repiace. 7. Incorrect engine coolant. Change. Idling or low-speed | 1. Extremely low ambient temperature. | Install radiator cover trouble. 2. Stuck thermastat (in fully-opened position). | Repiace. CARBURETOR ‘Complaint ‘Symptom and possible causes Remedy Starting difficulty. | 1, Clogged starter jet. Clean. 2, Clogged starter jet pipe. Clean. ‘8. Air leaking from carburetor joint. Tighten or replace detective part 4, Improperly working starter valve. Check and adjust. Tiling or low-speed | 1. Clogged or loose pilot jt Clean or tighten. trouble. 2. Air leaking from carburetor joint. Tighten or replace defective part. 3. Improperly adjusted pilot air screw. Adjust Medium-or high 1. Clogged main jet. Clean speed trouble. 2, Clogged needle jet Clean 3. Incorrect float chamber fuel level Adjust float height 4, Improperly working throttle valve Adjust. 5. Clogged fuel fier. Clean or repiace. Overflow and fuel | 1. Wor or damaged needle valve. Replace. level fluctuations. | 2, Broken needle valve spring Replace. 3. Improperly working float. Adjust or replace. 4. Foreign matter on the needle valve. Clean or repiace with needle valve seat 5. Incorrect float chamber fuel level Agjust float height 8. Clogged carburetor air vent hose. Clean CHASSIS ‘Complaint ‘Symptom and possible causes Remedy Steering is heavy. | 1. Overtightened steering stem nut Adjust 2. Broken bearing/ace in steering stem. Replace. 3. Distorted steering stem, Replace. 4. Low tire pressure. Regulate. Handlebar wobbles. | 1. Loss of balance between right and left front forks. | Adjust or replace 2. Distorted front fork Repair or replace. 3. Distorted front axle Replace. 4. Twisted tre Replace.85 SERVICING INFORMATION Complaint ‘Symptom and possible causes Remedy Front wheel wobbles. | 1. Distorted wheel rim. Replace. 2. Worn front wheel bearing. Replace. 8, Defective or incorrect tire. Replace. 4, Loose front axle nut. Tighten. 5. Loose front axle pinch bott Tighten. 6. Incorrect fork oil level. Adjust. Front suspension 1, Weak spring Replace. too soft. 2. Insufficient fork oil Check level and add. 3, Improper suspension setting. Adjust. 1, Excessively viscous fork il. Replace. 2. Excessive fork ol ‘Check level and drain, 3, Improper suspension setting, Adjust. Front suspension 1. Insufficient fork oil. Check level and add, too noisy. 2, Loose front suspension fastener. Tighten, Rear wheel wobbles. | 1. Distorted wheel rim. Replace. 2. Worn rear wheel bearing. Replace. 8. Detective or incorrect tire. Replace. 4. Worn swingarm bearing. Replace. 5. Worn rear suspension bush. Replace. 6. Loose rear suspension fastener. Tighten, Rear suspension too | 1. Weak rear shock absorber spring. Replace. soft. 2. Rear shock absorber leaks oil Replace. 3. Improper suspension setting, | Adjust. Rear suspension too | 1. Improper suspension setting, ‘Adjust. stiff. 2. Bent rear shock absorber shaft, Replace. 3. Bent swingarm. Replace. 4, Worn swingarm and rear suspension related Replace. bearings. Rear suspension too | 1. Loose rear suspension fastener. Tighten. noisy. 2. Worn rear suspension bush. Replace. 3. Worn swingarm bearing. Replace. BRAKES ‘Complaint ‘Symptom and possible causes Remedy Brake power 1. Leakage of brake fluid, Repair or replace. insufficient. 2. Worn brake pad. Replace. 3. Ollon brake pad surface, Clean brake disc and brake pads. 4. Worn brake disc. Replace. 5. Air in hydraulic system. Bleed.‘SERVICING INFORMATION _ 86 ‘Complaint ‘Symptom and possible causes Remedy Brake squeaks. Carbon adhesion on brake pad surface. Tilted brake pad. Clean surface with sandpaper. Readjust brake pad position or replace, 3. Damaged wheel bearing Replace. 4. Worn brake pad. Replace. 5. Foreign material in brake fluid ‘Change brake fluid. 6. Clogged return port of master cylinder. Disassemble and clean master cylinder. 7. Loose front or rear axle nut Tighten. Brake lever or pedal | 1. Airin hydraulic system Bleed. stroke excessive. | 2. Insufficient brake fluid Check level and add. Bleed any ai. 8. Incorrect brake fluid Change. Brake fiuid leaks. 41. Loose connection joint Tighten. 2. Cracked hose. Replace. 3. Worn piston seal Replace. 4. Worn secondary cup. Replace. Brake drags. 4. Rusty part. Clean and lubricate 2. Insufficient brake lever or brake pedal pivot Lubricate lubrication. ELECTRICAL Complaint ‘Symptom and possible causes Remedy No sparking or poor | 1. Defective ignition coil Replace. ‘sparking. 2. Detective spark plug Replace. 8. Detective pick-up coil Replace. 4. Detective stator col Replace. 8. Detective CDI unit Replace. Spark plug is wet or | 1. Excessively rich airituel mixture, Adjust carburetor. quickly becomes 2. Excessively high idling speed Adjust carburetor. fouled with carbon. | 3. Incorrect gasoline. Change. 4, Dirty air cleaner element. Clean or replace. 5. Incorrect spark plug (cold type). Change to hot type spark Plug. 6. Incorrect engine oil Change. ‘Spark plug quickly | 1. Worn piston ring. Replace. becomes fouled with | 2. Worn piston Replace, oil or carbon. 3. Worn cylinder. Replace, ‘Spark plug 1. Incorrect spark plug (hot type). Change to cold type spark electrodes overheat plug. or burn. 2. Overheated engine. Tune-up. 8, Loose spark plug. Tighten. 4, Excessively lean airfuel mixture. Adjust carburetor.“Se “_ WIRING DIAGRAM 8-7_ SERVICING INFORMATION EeSERVICING INFORMATION 8-8 WIRE, CABLE, AND HOSE ROUTING WIRE ROUTING89 SERVICING INFORMATION. CABLE ROUTINGSERVICING INFORMATION 8-10 FUEL HOSE ROUTING8-11_ SERVICING INFORMATION COOLING SYSTEM HOSE ROUTINGSERVICING INFORMATION _8-12 Rasiator Radiator Upper radiator hose No.1 Upper radiator hose No.2 CConneet the hase andatign the ite-pain mark ot faces towards ‘he rear of the motoreyte. Radiator Lower rasiator hose Radiator outlet hose813 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING After touching the brake hose union ‘othe topper tighten the union balt to the specties torque. Trot cD ware hose CCteh cable Hose clamp (Clamp the brake hose in the Center ofthe rubber sheave Ate touching the brake hose union to the stopper, tighten the union bolt to the specifies torque. Brake Caliper‘SERVICING INFORMATION 8-14 REAR BRAKE HOSE ROUTING ‘After touching the brake hose union to the stopper ghten the union bolt to the specified torque. After touching the brake hose union — tothe stopper, tighten the union bolt to the spectied torque. Brake caliper Bhike hose. we)8415 _ SERVICING INFORMATION SPECIAL TOOLS 9900-00401 9900-00810 Hexagon wrench | Hexagon wrench | 08000-06104 09900-06105 09900-06108 = o- Snap ring piers _|Snapring pliers | Snap ring pliers Cts eS é 9000-20208 9900-20508 09900-20102 Micrometer Cyfinder gauge set 9900-08004 Vernier calipers | (1/100 mm, (1/1000 mm, (17100 mn, Impact driver set _| (1220 mm, 200 mm) | 50-76 mm) 0-25 mm) 0-80 mm) 09900-20608 09900-20602 Dial calipers 09900-20606 Dial gouge (1/100 mm, Dial gauge 09900-20701 9900-20808 (1/1000 mm) 10-34 mm) (4/100 mm) [Magnetic stand _| Thickness gauge 09900-21304 09900-22401 | 09900-25008 9900-20805 | V.block set | small pore gauge 09900-25002 Mult cireuit tester Tire depth gauge | (100 mm) (10-18 mm) Pocket tester | set eZ 09910-60611 09900-28108 | 09900-26006, 09910-20116 09910-32812 Electrotester | Tachometer Conrod holder | Crankshaft installerSERVICING INFORMATION 8-16 wv %S 09913-50121 09913-70122 09913-84510 09913-85210 09913-80112 Oil seal remover | Bearing installer__| Bearing installer___| Bearing installer__| Bearing installer NN @ 09920-13120 09920-53740 09923-74510 Crankcase separat- | Clutch sleeve hub | 09923-73210 Bearing remover | 09924-84511 ing tool holder Bearing remover _| (20-35 mm) Bearing installer set 09925-18010 (09930-10121 (09930-30113 09924-84521 Steering bearing —_| Spark plug wrench | 09930-30102 Flywheel rotor Bearing installer set | installer set Sliding shaft remover 09930-40131 09940-14911 09940-14960 09990-30133, 09990-40113, Rotor holder attach- | Steering stem nut | Steering stem nut Rotor remover set_| Rotor holder ment wrench wrench socket 09940-52841 09940-52861 09940-52890 Front fork inner rod | Front fork oil seal | Front fork assembly | 09940-94922 09941-34513 holder installer tool ‘Stopper plate | Bearing installer47_ SERVICING INFORMATION BLS Fork oil level gauge Bearing installer 09941-54911 09943-88211 09941-50111 Bearing outer race | 09941-74910 Bearing remover/ | 09941-84510 Bearing remover _| remover Bearing installer__| installer Bearing remover 09943-74111 09922-55131SERVICING INFORMATION 8-18 TIGHTENING TORQUE ENGINE TEM Nm kg-m Ibeft Cylinder head nut 28 28 20.0 Spark plug 28 28 20.0 Cylinder nut 38 38 275 Magneto rotor nut 80 80 58.0 Clutch sleeve hub nut 90 EX) 65.0 Primary drive gear nut 90 9.0 65.0 Exhaust vaive arm bolt 10 10 70 Engine mounting nut (front upper) a aa 29.5 Engine mounting nut (lower) 4 44 295 CHASSIS ITEM Nm kg-m Ibeft Handiebar clamp bolt 26 26 19.0 Handlebar holder nut | 5 45 32.5 Front fork upper clamp bolt 26 26 | (190 Front fork lower clamp bolt 26 26 I 19.0 Steering stem head nut 90 30 65.0 Steering stem nut 4% 45 325 Front fork cap bolt 23 23 165 Front fork center bolt 80 80 58.0 Front fork piston rod locknut 22 22 16.0 Front brake master cylinder mounting bolt 10 1.0 70 Rear brake master cylinder mounting bolt 10 10) 70 Brake hose union bolt (front & rear) 23 23 165 Brake caliper mounting bolt (front & rear) 26 26 19.0 Brake pad mounting pin (front & rear) 18 18 13.0 Brake air bleeder valve (front & rear) a 08 60 Rear brake pedal bolt 23 29 21.0 Brake disc bolt (rent & rear) 10 10) 7.0 Front axle 65 65 470 Front axle holder bolt 18 18 13.0 Engine mounting plate nut (upper & front) 44 44 32.0 ‘Seat rail mounting bolt (upper) 26 26 19.0 ‘Seat rail mounting bot (lower) 23 23 165 Rear axle nut 140 11.0 79.5 Rear sprocket nut 28 28 20.0 Drive chain roller mounting bolt aa 44 29.5 ‘Spoke nipple (Front & rear) 25 0.25 18 ‘Swingarm pivot nut 79 79 57.08419 _ SERVICING INFORMATION —__—aAaAEH——_—-Tw SSS ITEM Nm kg-m Ib-ft Rear shock absorber mounting nut (upper & lower) 55 55 40.0 Cushion lever mounting nut (center) 100 10.0 725 Cushion lever mounting nut (front) 80 80 58.0 Cushion rod mounting nut 700) 10.0 725 TIGHTENING TORQUE CHART For other bolts and nuts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt marked bolt @ (mm Nm | kgm Ibeft Nem kg-m lb-ft 4 15 0.45 1.0 2 02 15 5 3 03 20 5 05 35 6 6 06 45 10 1.0 7.0 8 13 13 95 23 23 165 10 29 29 21.0 50. 50 36.0 12 45 45 32.5 85 85 615 14 65 65 470 135 135 o75 16 105 10.5 760 210 21.0 152.0 18 160 | 160 1155 240) 24.0 1735. onm«t) cmt ax ® Conventional bolt “4” marked bolt “7" marked boltSERVICING INFORMATION 8-20 SERVICE DATA CYLINDER + PISTON + PISTON RING Unit: mm (in) TEM STANDARD UMIT. Piston-to-cylinder clearance (0.050-0.080 0.120 (0.0020-0.0031) (0.0047) Gylinder bore 67.000-67.015 (2.6377-2.6364) - Measure 20 (0.8) from the top surface Piston diameter 66.950-66.965 cease ses, oS Measure 24 (0.8) from the skirt end Cylinder distortion _ 0.05 (0.002) Cylinder head distortion _ 0.05 (0.002) Piston ring end gap 0.20-0.40 0.85 (0.008-0.016) (0.083) Piston-ring-to-pisten-ring-groove 0.020-0.060 _ clearance (0.0008-0.0024) Piston pin bore 18.000-18.006 18.030 (0.7087-0.7088) (0.7098) Piston pin OD. 17.995-18.000 17.980 (0.7085-0.7087) (0.7079) CONROD + CRANKSHAFT Unit: mm (in) TEM ‘STANDARD cin Conrod small end |. 23.003-23.011 23.040 (0.9056~-0.059) (0.8071) Crank-web-to-crank-web width 58.0201 (2.283:0,004) = Crankshaft runout _ 0.05 (0.002) CLUTCH Unit: mm (in) TEM ‘STANDARD. cM Clutch cable play 10-15 _ (04-06) Clutch drive plate thickness 27-29 24 (0.106-0.114) (0.094) Clutch drive plate claw width 158-160 153 (0.62-0.63) (0.60) Clutch drive plate distortion _ 0.10 (0.004) Clutch spring free engih _ 455 (1.79) RADIATOR Unit: mm (in) TEM ‘STANDARD TMT Radiator cap valve release pressure 110 kPa (1.1 kg/om?, 16 psi)&:21_ SERVICING INFORMATION TRANSMISSION Unit: mm (in) Except ratio TEM ‘STANDARD TIMI Primary reduction ratio 2.652 (61/23) = Final reduction ratio 3.846 (50/13) = Gear ratios Low 2.285 (32/14) = 2nd 1.733 (26/15) = 3rd 1.375 (22/16) = ath 7,090 (24/22) [ S Top 0.865 (19/22) | = Gearshift forkcto-gearshift-fork- 01-03 05 groove clearance (0.004-0.012) (0.02) Gearshift fork grcove width 48-49 _ (0.189-0.193) Gearshift fork thiekness 46-47 _ (0.181-0.185) DRIVE CHAIN Unit: mm (in) Except ratio TEM ‘STANDARD. LIMIT Drive chain ‘Type RK520SMOZ9 = Links 114 = 20-pitch length = as, Drive chain slack 45-55 _ (18-22) CARBURETOR TEM SPECIFICATION Carburetor type KEIHIN Pue Bore size 38mm LD. No. ‘4482 Idle min, 1150-1 250 Float height 16.02 1.0 mm (0,630.04 in) Main jet (Md) #175 Main air jot (MAS) #200 Jet needle GN) RV472L1L-2nd Cutaway (CA) #5 Slow jet (Ga) #55 By-pass (@P) (0.8 mm (0.031 in) Pilot outlet (PO) (0.7 mm (0.028 in) Air screw (S) “tum out Throttle cable play 3.0-6.0 mm (0.12-0.24 in) at the throttle grip‘SERVICING INFORMATION _ 8-22 BRAKE + WHEEL Unit: mm in) TEM STANDARD TMT Brake lever play oni _ (0.004-0.01) Rear brake pedal play 5-15 _ (02-06) Rear brake pedal height ot) _ (0-04) Brake disc thickness — 3.0202 25 (0.118:0.008) (0.10) 45202 | 40 Rear (0.1770.008) (0.16) Brake disc runout Front & _ | 0:30 Rear (0.01) Master oylinder bore an TS, _ 12,700-12.743 mea (0.5000-0.5017) — Master cylinder piston diameter = 12.657-12,684 (0.4983-0.4994) ~ 12.657—-12.084 cosy (0.4983-0.4994) = Brake caliper oylinder bore aa (77000-27050 _ 0630-1. 27.000-27.050 ey (4.0830—1.6650) = Brake caliper piston clameter a (75,900-26 380 _ 0591-1. 26.900-26.950 Ga (1.0591-1.0610) = Wheel rim runout ar _ 20 (0.08) 2.0 Radial = ay Wheel axie runout a _ ees) 0.25 Rear - (any Tire size Front 300-21 SIP = | Rear 120/90-18 65P = Tire wead depth = _ oy 40 Rear - ony8:23 SERVICING INFORMATION SUSPENSION Unit: mm (in) TEM ‘STANDARD TMT NOTE Front fork stroke 297 _ (11.8) Front fork spring free length ] _ 5255 (20.7) Front fork spring rate 7.65 Nimm _ (0.78 kgfimm) | Front fork oil level 109 _ (43) Front fork air pressure ‘OkBa _ (0 kg/cm?, 0 psi) Rear shock absorber gas pressure 1009 KPa _ (10 kg/em?, 142 psi) Rear shock absorber spring rate 44.1 Nimm _ (4.5 katimm) Rear shock absorber spring pre-set 263.8 _ length (10.4) Rear wheel travel 314 (12.3) = ‘Swingarm pivot shaft runout _ 03 (001) TIRE PRESSURE 150 KPa Front & Rear 1.80 kg/om? 22 psi ELECTRICAL Unit: mm (in) TEM I ‘SPECIFICATION NOTE Ignition timing 4.0°BT.DC. at 1 500 ¢/min. Spark plug) Type NGK: BROEV 05-06 oD (0.020-0.024) Spark performance Over 6 (0.5) at 1 atm. Ignition coil resistance Primary oa Terminal-Ground ‘Secondary 15-18 kD Plug cap-Ground Magneto coil resistance Pick-up coil ai 121 Br-W Charging coil 06-079 Y-¥ Regulated voltage 18.5-14.5 V at 5 000 r/minSERVICING INFORMATION 8-24 WATTAGE Unie w Trew SPECIFICATION Headlight Hi 60 Lo 85 Brake lightiailight Bai Turn signal lights 21 ‘Speedometer light 17 Turn signal indicator ight 20 High beam indicato" light 2.0 Neutral indicator ligt 2.0 FUEL + OIL + COOLANT TEM ‘SPECIFICATION NOTE Fueltype Unleaded gasoline minimum 95 octane (RON) Fuel tank capaci HSL pacity Including reserve (3.02.3 Usiimp gal) 25L eserve only (0.7/0.5 US/imp gal) | Engine oll type BP RACING TR ° SHELL SPORTS SX MOTUL 800 2T CASTROL A747 “Transmission oil type ‘SAE 10W/40 “Transmission oil capacity 650 mi Change (0.7/0.6 US/imp qt) 750 mi ceteul (0.8/0.7 US/imp a!) Front fork oil type ‘SUZUKI fork oil SS-05 or an equivalent fork oil Front fork oll capacity (each leg) 639 mi (21.6/22.5 US/Imp oz) Coolant type Use an anti-freeze & summer coolant compatible with | aluminum radiator, mixed with distilled water only, at the ratio | of 50 : 50 Coolant capacity 4470 mi (1.9/1.1 US/imp at) Rear shock absorber oil ‘SUZUKI Rear suspension oil SS-25 or an equivalent rear type suspension oil Rear shock absorber oil 345 mi capacity (11.712.1 US/Imp qt) Brake fluid type. DoT 4RMX250SX (’99-MODEL) CONTENTS SPECIFICATIONS .....--.. 0002225 SERVICE DATAS41_RMX250SX (99-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length Overall width Overall height Wheelbase Ground clearance Seat height Dry mass . ENGINE Type... cooledintake system . . Number of cylinders Bore Stroke Displacement Compression ratio .. Carburetor. Air cleaner Starter system . Lubrication system TRANSMISSION Clutch — Transmission Gearshift pattern Primary reduction ratio Gear ratios, 1st (low) 2nd... 3rd ath sth (top) Final reduction ratio . Drive chain .... 2.260 mm (89.0 in) 880 mm (34.6 in) 1275 mm (50.2 in) 1480 mm (58.3 in) 325 mm (12.8 in) 945 mm (37.2 in) 113 kg (249 Ibs) Two-stroke, liquid Crankcase reed valve 1 67.0 mm (2.637 in) 70.8 mm (2.787 in) 249 cm? (15.2 cu. in) 83: 1103:1 KEIHIN PJ38, single Polyurethane foam element Primary kick Fuelol preminture of $2: 1 Wet multi-plate type 5-speed constant mesh 1-down, 4-up 2.652 (61/23) 2.285 (32/14) 1.738 (26/15) 1.375 (22/16) 1.090 (24/22) 0.863 (19/22) 3.846 (50/13) RK520SMOZ9, 114 links CHASSIS Front suspension Rear suspension . Caster Trail : Steering angle Tuming radius Front brake Rear brake .. Front tire size Rear tire size ELECTRICAL Ignition type ..... Ignition timing Spark plug Generator Headlight Turn signal light Brake light/tallight Speedometer light Neutral indicator light High beam indicator light Tum signal indicator ight CAPACITIES Fuel tank including reserve Reserve Transmission oil Engine coolant “These specifications are subject to change without notice. Telescopic, coil spring, oil damped, spring preload fully adjustable, ‘compression damping force 18-way adjustable, rebound damping force 14-way adjustable Link type, gas/eoil spring, oil damped, spring preload fully adjustable, ‘compression damping force 21-way adjustable, rebound damping force 26-way adjustable 28° 111 mm (4.4 in) 45° (right & left) 2.3 m (75 ft) Disc Disc 3.00-21 51P, tube 120/90-18 65P, tube Electronic ignition (CDI) 4° B.T.D.C, at 1500 r/min NGK BROEV Flywheel magneto 12V 60/S5W 12 21W 12V 21/5w 12V 1.7W 12V 2W 12V 2W 12V 2W 11.5 L (8.02.5 US/Imp gal) 2.5L (0.7/0.5 US/Imp gal) 650 mi (0.7/0.6 US/Imp qt) 1.2L (1.3/1.1 US/Imp qt)SERVICE DATA RMX250SX (39-MODEL) 9-2 CYLINDER + PISTON + PISTON RING Unit: mm (in) TEM ‘STANDARD LiMir Piston-to-cylinder clearance 0.050-0.080 0.120 (0.0020-0.0031) (0.0047) Cylinder bore 67.000-67.015 (2.6377-2.6384) — Measure 20 (0.8) from the top surface, Piston diameter 66.950-66.965 (2.6358-2.6364) es Measure 24 (0.9) from the skirt end. Z Cylinder distortion 0.05 (0.002) Cylinder head distortion 0.05 (0.002) Piston ring end gap 0.20-0.40 0.85 (0.008-0.016) (0.033) Piston-ring-to-piston-ting-groove 0.020-0.060 clearance (0.0008-0.0024) Piston pin bore 18.000-18.006 18.030 (0.7087-0.7088) (0.7098) Piston pin O.D. 17,995— 18.000 17.980 (0.7085-0.7087) (0.7079) CONROD + CRANKSHAFT Unit: mm (in) TEM ‘STANDARD uiMiT Conrod small end LD. 23.003-23.011 23.040 (0.9056-0.9059) (0.3071) Crankeweb-to-crank-web width 58.0=0.1 (2.283 + 0.004) Crankshaft runout 005 (0.002) CLUTCH Unit: mm (in) TEM ‘STANDARD LIMIT Clutch cable play 10-15 (0.4-0.6) Clutch drive plate thickness 27-29 2a (0.106-0.114) (0.094) Clutch drive plate claw width 15.8-16.0 153 (0.62-0.63) (0.60) Clutch driven plate distortion 0.10 (0.004) Clutch spring free length 455 (1.79) RADIATOR TEM ‘STANDARD LiMiT Radiator cap valve release pressure 110 kPa (1.1 kg/em?, 16 psi)TRANSMISSION Unit: mm (in) Except ratio ITEM ‘STANDARD Limit Primary reduction ratio 2.652 (61/23) Final reduction ratio 3.846 (50/13) Gear ratios Low 2.285 (32/14) — 2nd 1.783 (26/15) — 3rd 1.875 (22/16) —— ath 7,080 (24/22) — Top 0.863 (19/22) — ‘Gearshift-fork-to-gearshift-fork- 01-03 05 groove clearance (0.004-0.012) (0.02) Gearshift fork groove width 48-49 (0.189-0.193) Gearshift fork thickness 46-47 (0.181-0.185) DRIVE CHAIN Unit: mm ITEM ‘STANDARD uM Drive chain Type RRK520SMOZ9 = Links 14 — | 20-piteh length — Gasn Drive chain slack 45-55 (1.8-2.2) CARBURETOR ITEM ‘SPECIFICATION Carburetor type KEIHIN P38 Bore size 38 mm 1D. No. 44E2 Idle r/min. 1150-1 250 Float height 16.0 = 1.0 mm (0.63 = 0.04 in) Main jet (My Wi75 Main air jet (MAS) #200 Jet needle’ GN] Ria72LiL-2nd Cutaway (CAy 6 Slow jet ) #55 By-pass (BP) (0.8 mm (0.084 in) Pitot outlet (PO) (0.7 mm (0.028 in) Air screw (@S) tum out Throttle cable play '3.0-6.0 mm (0.12—0.24 in) at the throttle gripRMX250SX (39-MODEL) 9. BRAKE + WHEEL Unit: mm (in) TEM STANDARD Mit Brake lever play 01-03 (0.004~0.01) Rear brake pedal play 5-15 (0.2-06) Rear brake pedal height 0-10 (0-04) Brake disc thickress 30202 25 Front (0.118 + 0.008) @.10 | i 45202 40 poy (0.177 =0.008) (0.16) Brake disc runout Front & 0.30 Rear (0.01) Master cylinder bore Fan 72.700-12.743 (0.5000-0.5017) 72.700-12.743 co (05000-0.5017) Master eylinder piston diameter | pron 12.657—12.684 (0.4983-0.4994) 12.657—12.684 pose (0.4983-0.4994) Brake caliper oyinder bore = 27.000-27.050 (1.0830-1.6650) 27.000-27.050 oo (1.0830- 1.6650) Brake caliper piston diameter pan 26,900-26.950 (1.0591-1.0610) 26.900-26.950 oa (4.0581 1.0610) Wheel rim runout 20 Axial = ee | 20 Radial = ae Wheel axle runout 0.25 Front (ean 0.25 Rear (0.010) | Tire size Front 300-21 51P Rear 720/90-18 65P Tire tread depth 40 Front (ony 4.0 Rear an9-5 _RMX250SX ('99-MODEL) SUSPENSION Unit: mm (in) (TEN ‘STANDARD uiMIT [__NOTE Front fork stroke 297 | (11.6) | Front fork spring free length 5255 ] (20.7) Front fork spring rate 7.65 Nimm (0.78 kgf/mm) Front fork oil level 109 (43) Front fork air pressure ‘OkPa (0 kg/cm?, 0 psi) Rear shock absorber gas 1000 kPa pressure (10 kglcm?, 142 psi) Rear shock absorber spring rate 44.1 Nimm (4.5 kgfimm) Rear shock absorber spring 263.8 pre-set length (10.4) Rear wheel travel 314 (12.3) ‘Swingarm pivot shaft runout 03 (0.01) TIRE PRESSURE 150 kPa Front & Rear 1.50 kgfen? 22 psi ELECTRICAL Unit: mm (in) TEM ‘SPECIFICATION NOTE Ignition timing 4.0°BTD.C. at 1 500 rimin. ‘Spark plug Type NGK: BROEV 05-06 Gap (0.020-0.024) ‘Spark performance Over 8 (0.3) at f atm. Ignition coil resistance Terminal Primary 0-19 eat z Plug cap- Secondary 15-18 kQ "ug cap: Magneto coil resisiance Pick-up coil ai-121 2 Br-W Charging coil 06-0.7 2 Y-¥ Regulated voltage 18.5—14.5V at § 000 r/minRMX250SX ('99-MODEL) 9-6 WATTAGE Unit: W_ TEM SPECIFICATION Headlight HI 60 Lo 35 Brake lightfalight 25 Turn signal lights 21 Speedometer light 17 Turn signal indicator ight 20 High beam indicator light 2.0 Neutral indicator light 2.0 FUEL + OIL + COOLANT TEM SPECIFICATION NOTE Fuel type Unleaded gasoline minimum 95 octane (RON) Fuel tank capacity Including reserve | noe susie oat Reserveony | (e705 US/imp ga) Engine oil type BP. RACING oT-A, SHELL SPORTS SX MOTUL 800 27 CASTROL A747 Transmission olltype ‘SAE 10W/40 Transmission oil capacity err (070 pa) jeceu (0.8107 USTInp at) Front fork oll ype SUZUKI fork off SS-08 or an equivalent fork oll Front fork oll capacity 639 ml (each leg) (21.6/22.5 US/Imp 02) Coolant type Use an antifreeze & summer coolant compatible | with aluminum radiator, mixed with distilled water | only, at the ratio of 50': 50. Coolant capacity 7470 mi (1.3/1.1 US/imp at) Rear shock absorber oil type ‘SUZUKI Rear suspension oll SS-25 or an equivalent rear suspension oll Rear shock absorber oil capacity 345 mi (11.712.1 US/Imp 02) Brake fluid type DoT4Prepared by ‘SUZUKI MOTOR CORPORATION Motorcycle Service Department 2nd Ed. May, 1998 Ist Ed, March, 1998 Part No. 99500-22071-01E Printed in JapanSUZUKI MOTOR CORPORATION CCR Uns wx

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